Ultrasonic-Welded Sensor Enclosure With Integrated Optical Elements
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Solution Overview
Problem
Existing sensor enclosures for monitoring stations face issues with maintaining a seal against environmental factors and optical path disruptions, particularly when using glued windows or direct lens mounting, which can lead to leaks and interference with electromagnetic waves.
Innovation Solution
A sensor enclosure with a housing made of transparent polypropylene, featuring integrated optical elements and a permanent connection via ultrasonic welding, utilizing stabilizing grooves and protrusions to ensure a tight and stable joint, eliminating additional components and enhancing optical path integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If windows are glued into openings in the sensor assembly enclosure, then the seal against environmental factors is maintained, but the optical path is disrupted and additional components increase device complexity
Solution Approach 1:
The patent merges the window function with the enclosure housing itself by making the housing material permeable to electromagnetic waves. This eliminates the need for separate window components while maintaining environmental sealing, directly resolving the contradiction between seal integrity and device complexity
Solution Approach 2:
The patent changes the material parameter of the enclosure housing to be permeable to electromagnetic waves while maintaining mechanical sealing properties. This allows the housing to simultaneously serve as both the enclosure and the optical window, eliminating additional components while preserving seal integrity
2Device complexity
If a lens is directly mounted in the enclosure opening, then optical path disruption is reduced, but the seal against environmental factors is compromised
Solution Approach 1:
The patent combines the lens function with the enclosure housing by integrating optical elements directly into the permeable housing structure. This eliminates the need for separate lens mounting components while maintaining environmental sealing through the permanent ultrasonic weld connection
Solution Approach 2:
The optical elements are integrated into the housing during the molding process before final assembly. This preliminary integration ensures that the optical path is optimized while the ultrasonic welding subsequently provides the environmental seal without requiring additional mounting steps that could compromise sealing
3Reliability
If the enclosure housing is made permeable to electromagnetic waves, then optical sensor operation is enabled, but protection against environmental factors is reduced
Solution Approach 1:
The patent changes the material parameters of the housing to achieve simultaneous electromagnetic wave permeability and environmental sealing. The housing material is selected to allow electromagnetic waves to pass through while maintaining mechanical integrity to protect against dust, moisture, and other environmental factors
Solution Approach 2:
The patent employs composite material properties in the housing that combine electromagnetic permeability with environmental resistance. The housing material exhibits dual characteristics: transparency to electromagnetic waves for sensor operation and impermeability to environmental contaminants for protection
4Reliability
If additional components such as windows and lenses are used, then optical functionality is achieved, but production costs and assembly complexity increase
Solution Approach 1:
The patent merges multiple functions (enclosure, window, lens mounting) into a single integrated housing structure. This reduces the number of bill of materials items and eliminates assembly steps for installing separate components, directly reducing production costs while maintaining optical functionality
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: providing environmental protection, enabling optical wave passage, and supporting optical elements. This multi-functionality eliminates the need for separate dedicated components for each function, simplifying manufacturing and reducing costs
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 complete sealing against external factors, reduces optical interference, and lowers production costs by integrating lenses into the enclosure, ensuring effective operation and ease of assembly.
Implementation Method 1
The invention is characterised by the permanent and tight connection of the upper and lower parts using ultrasonic welding
Implementation Method 2
the enclosure, at the location corresponding to the sensor's optical path, containing at least one integrated optical element, which focuses electromagnetic waves within the wavelength range corresponding to the operating range of the optical sensor
Implementation Method 3
a housing with an upper and lower part, both made from a material permeable to electromagnetic waves
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
The sensor enclosure (1) comprising an enclosure housing, which includes an upper part (10) and a lower part (20), made from a material permeable to electromagnetic waves. The sensor enclosure is characterised by the upper part (10) and lower part (20) of the enclosure housing being permanently and tightly connected using ultrasonic welding. The subject of the application also includes a sensor assembly housed within the enclosure according to the invention.