Snap-fit Sensor Assembly Eliminating Leak Paths
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Solution Overview
Problem
The existing manufacturing process for sensor housings often results in 'touching out' issues, where the sensor body comes into contact with the mold, leading to potential leak paths and increased labor due to the need for precise placement, which can cause damage and corrosion.
Innovation Solution
A two-piece sensor assembly with a thermoplastic sensor body insert that uses a spherical-type snap-fit mechanism to eliminate leak paths and simplify assembly, featuring a thermoplastic sensor body molding with an arcuate ring that deforms to interface with a corresponding sensor housing, ensuring complete coverage and secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sensor body is placed into the center of the injection mold for precise placement, then the sensor body can be properly positioned, but the process becomes labor intensive and the sensor body may still touch out during injection
Solution Approach 1:
The invention divides the sensor assembly into two separate pieces: the sensor body and the sensor housing. The sensor body is pre-assembled with its own housing, and then this complete unit is inserted into the final sensor housing. This segmentation eliminates the need for precise centering during injection molding, as the sensor body is no longer directly molded in place but rather inserted as a pre-assembled unit.
Solution Approach 2:
The sensor body is pre-housed in a separate molding operation before being inserted into the final sensor housing. This preliminary action of pre-assembling the sensor body with its own housing eliminates the need for careful placement during the final assembly process, allowing for automated insertion without precision positioning requirements.
2Reliability
If the thermoplastic material is injected to fully encase the sensor body, then protection is improved, but the sensor body may touch out during injection creating leak paths
Solution Approach 1:
By separating the sensor body housing from the sensor housing, the invention eliminates the touching out problem entirely. The sensor body is completely encased in its own housing in a separate molding operation, ensuring no leak paths. The two housings are then joined via snap-fit mechanism, maintaining complete protection without the risks associated with in-mold positioning.
Solution Approach 2:
The invention introduces an intermediary structure - the sensor body housing - that acts as a mediator between the sensor body and the sensor housing. This intermediary component ensures complete encasement of the sensor body while providing a separate interface for connection to the sensor housing, eliminating the need for the thermoplastic material to flow around the sensor body during injection.
3Device complexity
If a traditional single-piece injection molded housing is used, then the structure is simple, but the sensor body may come into contact with the mold causing touching out
Solution Approach 1:
The housing structure is divided into two separate components: the sensor body housing and the sensor housing. This segmentation allows each component to be optimized independently - the sensor body housing provides complete encasement without mold contact, while the sensor housing provides the mounting interface. The snap-fit connection between the two maintains structural integrity while eliminating the touching out problem.
4Manufacturing precision
If the sensor body is carefully placed into the injection mold, then touching out can be avoided, but the manufacturing process becomes labor intensive
Solution Approach 1:
The sensor body is pre-assembled with its housing in a separate operation before insertion into the final sensor housing. This preliminary action eliminates the need for careful placement during the final assembly, as the pre-housed sensor body can be automatically inserted without precision positioning requirements, significantly improving manufacturing efficiency.
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 design effectively prevents damage from environmental exposure and reduces manufacturing labor by ensuring complete encasement of the sensor body and allowing for automated assembly with a secure snap-fit mechanism, minimizing the risk of tampering.
Implementation Method 1
a thermoplastic sensor body molding with an arcuate ring that deforms to interface with a corresponding sensor housing
Data Source
AI summary
A two-piece sensor assembly is disclosed comprising a sensor body insert having a thermoplastic sensor body molding that can be snap-fit into a thermoplastic sensor housing a spherical-type snap-fit eliminating leak paths or openings that may damage the sensor body.