Integrated Sensor-Plug for Automotive Condenser Drier Bottles
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Solution Overview
Problem
The existing automotive air conditioning systems face issues with cross-threading and debris trapping due to the use of plastic threads in aluminum drier bottles, leading to inefficiencies and increased component complexity, weight, and cost.
Innovation Solution
A sensor-plug is integrated into the condenser drier bottle plug, forming a single unitary piece with a pressure or temperature sensor, which is secured via a threaded or retained connection and O-rings, reducing the need for separate sensors and components, and minimizing debris entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic thread-in plugs are used in aluminum drier bottles, then the plug can be easily manufactured and installed, but cross-threading and debris trapping occur leading to system reliability issues
Solution Approach 1:
The patent combines the plug body and sensor into a single integrated unit, eliminating the need for separate plastic threaded plugs that cause cross-threading. The integrated design features a sensor housing with external threads that directly engage the drier bottle, removing the problematic plastic-thread-aluminum-thread interface while maintaining ease of installation through the unified structure.
Solution Approach 2:
The patent introduces an intermediary threaded housing structure that mediates between the plug installation requirement and the drier bottle threading system. This housing provides the threading interface while containing the sensor, acting as a mediator that prevents direct engagement issues between dissimilar materials (plastic and aluminum) while ensuring reliable connection.
2Measurement precision
If separate sensors and Schrader valves are added to the condenser, then pressure and temperature monitoring capability is improved, but the overall weight and component complexity increase
Solution Approach 1:
The patent merges multiple functions (pressure sensing, temperature sensing, sealing, and structural support) into a single integrated plug assembly. The sensor housing contains both pressure and temperature sensors, while the O-ring provides sealing, and the threaded portion provides structural engagement, eliminating the need for separate Schrader valves and standalone sensors.
Solution Approach 2:
The plug assembly serves multiple functions simultaneously: it provides the sealing interface (O-ring), the structural connection (threaded housing), the pressure sensing capability (pressure sensor in housing), and the temperature sensing capability (temperature sensor in housing). This multi-functional design reduces component count while maintaining comprehensive monitoring capability.
3Ease of operation
If plastic threads are threaded into aluminum threads on the drier bottle, then the plug can be secured, but debris is generated and trapped inside the condenser system
Solution Approach 1:
The patent combines the threading function and sealing function into a single integrated housing structure. The threaded housing provides the connection interface while the O-ring provides the seal, eliminating the need for plastic threads engaging aluminum threads. This integration prevents debris generation from thread interaction while maintaining ease of installation through the unified threaded housing design.
4Adaptability or versatility
If multiple separate components (plug, sensor, Schrader valve) are used in the condenser, then each component can be optimized independently, but the overall system weight and cost increase
Solution Approach 1:
The patent combines multiple separate components (plug body, sensor assembly, sealing elements) into a single integrated unit. This consolidation reduces the total weight by eliminating redundant structural elements, fasteners, and separate mounting hardware while maintaining the ability to optimize each functional element (threaded housing for connection, O-ring for sealing, sensors for monitoring) within the unified design.
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
This solution reduces the overall weight and cost of the condenser, minimizes leak paths, and eliminates the need for additional components like Schrader valves, while enhancing the system's reliability by integrating the sensor directly into the plug, thus addressing cross-threading and debris issues.
Implementation Method 1
A seal is formed between the sensor-plug and the drier bottle via at least one O-ring on the sensor-plug
Data Source
AI summary
A sensor-plug for insertion into a drier bottle of an automotive condenser. The sensor-plug is a unitary piece and positioned within the drier bottle to eliminate the use of a separate sensor on the opposite side of the condenser.