Tire Pressure Sensor Insert Molding for Gas Leakage Prevention
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Solution Overview
Problem
Conventional tire pressure sensors experience gas leakage due to gaps between threaded housings and valve connectors, leading to inaccurate pressure readings, particularly in high-pressure applications like MRT trains, mining vehicles, and large trucks.
Innovation Solution
The tire pressure sensor structure integrates a housing, tire pressure sensor, and valve connector with a molding body formed via insert molding, which closes the opening and prevents gas leakage by creating a hermetic seal, using a base and connecting port to connect with the tire valve and fixing the tire pressure sensor internally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two housings are screwed together with threads to assemble the tire pressure sensor, then the sensing element can be placed into the inner space, but gas leaks outward along the thread gap causing measurement inaccuracy
Solution Approach 1:
The patent merges the two separate housings into a single integrated housing structure. The first housing and second housing are combined into one piece that includes both the receiving portion for the sensing element and the assembly portion for the valve connector, eliminating the threaded connection interface that caused gas leakage.
Solution Approach 2:
The integrated housing is divided into functional segments: a receiving portion that houses the sensing element and an assembly portion that interfaces with the valve connector. This segmentation allows the housing to fulfill multiple functions while maintaining gas-tight integrity throughout the structure.
2Strength
If the valve connector is fixed to the housing by a built-in nut requiring a center opening, then the valve connector can be securely attached, but gas leaks outward along the opening gap
Solution Approach 1:
The valve connector base and housing are merged into a single integrated structure. The assembly portion of the housing directly forms the mounting structure for the valve connector without requiring a separate nut and center opening, thereby eliminating the gas leakage path through the opening gap.
3Reliability
If a single integrated housing is used to eliminate thread gaps, then gas sealing is improved, but the structural complexity increases
Solution Approach 1:
The integrated housing is functionally segmented into a receiving portion and an assembly portion. This segmentation allows the housing to accommodate different components (sensing element and valve connector) while maintaining a gas-tight integrated structure, balancing sealing performance with structural organization.
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 volume of the tire pressure sensor, enhances airtightness, and improves measurement accuracy by eliminating gas leaks through a single insert molding process, adaptable to various vehicle tire sizes and types.
Implementation Method 1
The molding body is formed on the surface of the base and adjacent to the connecting port to close the opening
Data Source
AI summary
According to one aspect of the present disclosure, a tire pressure sensor structure includes a housing, a tire pressure sensor, a valve connector and a molding body. The housing is with an opening and has a receiving portion and an assembly portion. The receiving portion is located on the inner surface of the housing, and the assembly portion is located between the receiving portion and the opening. The tire pressure sensor is placed into the receiving portion. The valve connector includes a base and a connecting port. The base fixes with the assembly portion for limiting the tire pressure sensor. The connecting port protrudes from the base to connect a valve of a tire. The molding body is formed on the surface of the base and adjacent to the connecting port to close the opening.