Sensor Module Gap Design for Condensation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas sensors, particularly those detecting hydrogen, face instability due to condensation issues caused by temperature fluctuations, leading to inaccurate readings and operational misfunctions.
Innovation Solution
A sensor module design that includes a housing with a gas sensor element and a battery, held by a holder forming gaps between the housing and the surrounding environment, which prevents thermal continuity and uses a low thermal conductivity material to suppress condensation, ensuring stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the sensor module is placed in direct contact with the handhole part inner wall, then the structural simplicity is improved, but condensation occurs due to thermal conduction causing operational instability
Solution Approach 1:
The patent introduces a holder as an intermediary component between the sensor module housing and the handhole part inner wall. This holder creates a gap structure that prevents direct thermal conduction while maintaining the sensor module's fixed position. The holder acts as a mediator that isolates the sensor circuit from harmful thermal effects without requiring complex additional structures.
2Temperature
If thermal conduction is enhanced to the sensor module, then temperature control is improved, but condensation occurs leading to inaccurate readings
Solution Approach 1:
The patent extracts the sensor circuit from direct thermal contact with the handhole part by positioning it within a housing that is separated by gaps. This extraction removes the sensor circuit from the harmful thermal environment while maintaining the overall temperature control of the sensor module through the battery's thermal mass and insulation properties.
3Manufacturing precision
If the sensor module is held firmly against the handhole part, then the positioning accuracy is improved, but thermal continuity causes condensation and operational misfunctions
Solution Approach 1:
The patent employs a holder structure that provides flexible positioning of the sensor module within the handhole part. The holder maintains accurate positioning through its mechanical design while simultaneously creating thermal breaks that prevent condensation. This solution combines positioning functionality with thermal isolation without requiring rigid direct contact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively suppresses condensation around the sensor circuit, maintaining accurate readings and preventing operational misfunctions by maintaining a stable temperature and reducing thermal conduction.
Implementation Method 1
a holder holding the sensor module so that a gap is formed between the inner wall and the housing and between the housing and a first member under the housing
Data Source
AI summary
According to one embodiment, a sensor includes a handhole part, a sensor module, and a holder. The handhole part includes an inner wall. The sensor module is provided in the handhole part. The sensor module includes a housing, a sensor circuit provided in the housing, the sensor circuit including a gas sensor element, and a battery configured to supply electrical power to the sensor circuit. The holder holds the sensor module so that a gap is formed between the inner wall and the housing and between the housing and a first member under the housing.