Sensor Housing Sealing Geometry for Tool-Free IP68 Assembly
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Solution Overview
Problem
The existing sensor housing designs rely on screw connections for sealing between the cover and lower part, leading to variable force distribution and potential sealing issues, making them user-dependent and prone to stress peaks.
Innovation Solution
A sensor housing design featuring a terminal space with parallel or angled sealing surfaces, utilizing a circumferential sealing element that is independent of screw torque, ensuring consistent contact pressure and improved sealing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used to assemble the lower part and cover, then the housing can be securely connected, but the force distribution on the seal becomes variable and stress peaks occur
Solution Approach 1:
The connection part is divided into a lower part and a cover that can be assembled separately. The sealing function is segmented from the fastening function, with the seal arranged in a groove on the lower part and the cover having a corresponding engagement structure. This allows the sealing surface to be pressed uniformly without the stress concentration caused by screw connections.
Solution Approach 2:
The seal is positioned in a groove on the lower part with its sealing surface oriented perpendicular to the closing direction. The cover has a corresponding structure that presses the seal uniformly along the entire sealing surface. This local structural design ensures uniform force distribution exactly where needed (at the sealing interface) rather than concentrating force at screw locations.
2Strength
If screw connections are used for assembly, then the housing can be securely fastened, but the assembly process becomes user-dependent and requires tools
Solution Approach 1:
The connection part is designed with a self-aligning and self-latching mechanism. The cover has a structure that automatically engages with the lower part, pressing the seal uniformly in the groove. The assembly process is tool-free and does not require user skill or judgment, making it truly self-service. The housing connects securely through this automatic engagement mechanism without requiring screws or external fastening tools.
3Reliability
If the sealing surface is arranged perpendicular to the closing direction, then uniform contact pressure is achieved, but the seal is directly loaded by assembly force
Solution Approach 1:
The seal is positioned in a groove on the lower part, acting as an intermediary element between the cover and the lower part. The sealing surface of the seal is arranged perpendicular to the closing direction, which allows uniform contact pressure distribution. The groove structure and the cover's engagement feature work together to press the seal uniformly, distributing the assembly force along the entire sealing surface rather than concentrating it, thus reducing peak stress while maintaining reliable sealing.
Data Source
Figure 1~2b
Figure 3
AI summary
Sensor housing comprising a head section with a sensor chamber for receiving a sensor and a connection section adjoining the head section with a terminal chamber for receiving a terminal block, wherein the connection section comprises a terminal chamber lower part and a terminal chamber cover which are assembled in a closing direction such that the terminal chamber lower part and the terminal chamber cover adjoin each other and enclose the terminal chamber, the terminal chamber cover and the terminal chamber lower part each have a sealing surface, the sealing surfaces facing each other and extending approximately parallel to each other, the sealing surfaces each extending along a closed curve around a central axis extending parallel to the closing direction and each extending at an angle of at least 0° and at most 45° to the central axis,so that the distance between each sealing surface and the central axis in the closing direction is constant or decreases, and a circumferential sealing element is arranged between the sealing surface of the clamping chamber cover and the sealing surface of the clamping chamber base to seal the clamping chamber.