Sensor Mounting Element Gap-Free Fixation Under Vibration
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Solution Overview
Problem
Current temperature sensors for detecting flowing media, such as hydraulic fluids, face issues with adhesive fixation due to complex dispensing processes, unreliable adhesion under temperature changes, and potential damage from aggressive fluids, especially when exposed to mechanical stress like vibrations.
Innovation Solution
A mounting element with a receptacle design that accommodates sensors with undefined shapes, using a thixotropically formulated epoxy compound and mounting cams to ensure gap-free fixation and protection, preventing adhesive flow and maintaining media contact openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If adhesive is used to fix the temperature sensor, then the sensor can be permanently fixed, but the dispensing process becomes very complex and processing reliability is insufficient
Solution Approach 1:
The patent extracts the adhesive application complexity by using a self-retaining adhesive geometry where the adhesive is enclosed by an undercut structure. This eliminates the need for complex dispensing processes while maintaining permanent fixing stability, as the adhesive is automatically retained by the geometric undercut without requiring precise dispensing control.
Solution Approach 2:
The mounting element is segmented into distinct functional zones: a receptacle for the sensor pill, an undercut geometry for adhesive retention, and mounting cams for mechanical engagement. This segmentation allows each component to perform its specific function independently, simplifying the overall fixing mechanism while ensuring reliable sensor attachment.
2Stability of the object's composition
If adhesive is used to fix the temperature sensor, then permanent fixing is achieved, but adhesion reliability under temperature changes is insufficient
Solution Approach 1:
The patent applies beforehand cushioning by designing an undercut geometry that mechanically interlocks with the sensor pill. This geometric interlocking provides a backup fixing mechanism that cushions against adhesion failure under temperature changes, ensuring that even if adhesive bonds weaken, the mechanical undercut structure maintains secure attachment.
3Stability of the object's composition
If adhesive is used to fix the temperature sensor, then fixing is achieved, but mechanical stability may be lost due to aggressive hydraulic fluid effects on the adhesive
Solution Approach 1:
The patent extracts the adhesive from direct exposure to aggressive hydraulic fluids by enclosing it within the undercut geometry of the mounting element. This protective enclosure shields the adhesive from fluid degradation while maintaining its fixing function, preventing loss of mechanical stability caused by fluid-aggressive effects.
4Stability of the object's composition
If adhesive is used to fix the temperature sensor, then fixing is achieved, but adhesive may be carried over into the glass area worsening thermal properties
Solution Approach 1:
The patent applies local quality by providing a specifically designed adhesive application zone with undercut geometry that is spatially separated from the sensor glass area. This localized adhesive containment ensures adhesive is applied only where needed for fixing while preventing contamination of the glass area, thereby avoiding worsening of thermal properties in the sensor's active region.
5Ease of manufacture
If the sensor pill is mechanically fixed with gaps, then installation is simple, but damage to terminal wires occurs under mechanical stress
Solution Approach 1:
The patent segments the fixing mechanism into multiple independent elements: the receptacle for positioning, the undercut geometry for adhesive retention, and mounting cams for mechanical engagement. This segmented approach provides comprehensive mechanical protection against vibrations and shocks while maintaining simple installation through the self-aligning receptacle design.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating mounting cams and an undercut adhesive structure that are pre-designed to absorb and distribute mechanical stresses. This cushioning effect protects the sensor pill and terminal wires from damage under mechanical stress while maintaining simple installation procedures.
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 solution provides reliable, gap-free fixation and protection of temperature sensors from external damage, ensuring accurate and timely temperature measurements even under mechanical stress, while preventing adhesive contamination and maintaining media contact.
Implementation Method 1
use of a thixotropically formulated epoxy resin which, under the action of vibrations, flows and enables gap-free fixing of the sensor pill
Implementation Method 2
The sensor pill is inserted into the sensor receptacle and subsequently ultrasonic vibrations are applied in order to introduce the thixotropic filling compound into gaps which are present between the sensor pill and the sensor receptacle
Data Source
AI summary
A mounting element for receiving a sensor has a sensor receptacle having an essentially cylindrical or funnel-shaped geometry. The sensor receptacle has openings for wetting of the sensor by a medium. The sensor is fixed in the sensor receptacle without gaps or play by a filling compound, which is in turn mounted by a mechanical undercut.