Plastic Water Outlet Housing With Integrated Temperature Sensor
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Solution Overview
Problem
The existing water outlet housings for internal combustion engines made of plastic face issues with leakage risks and difficulties during maintenance interventions due to limited space in the engine compartment, which complicates disassembly and reuse of space.
Innovation Solution
A water outlet housing with a permanently integrated temperature sensor, either through overmolding or welding, eliminating the need for an O-ring and clip, and allowing for direct contact with water, thereby enhancing sealing and simplifying maintenance by integrating the sensor within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a temperature sensor is mounted on the water outlet housing with an O-ring and clip, then the sensor can be removed during maintenance, but leakage risk increases and maintenance becomes difficult due to limited space
Solution Approach 1:
The temperature sensor is permanently integrated into the water outlet housing through overmolding or welding, merging the sensor and housing into a single unified component. This eliminates the separate mounting structures (O-ring and clip) and their associated leakage risks, while the integrated design simplifies maintenance by reducing the number of parts and assembly steps required during service interventions.
2Reliability
If additional sealing components (O-ring and clip) are used to mount the sensor, then leakage is prevented, but device complexity increases
Solution Approach 1:
The sensor mounting structure is merged with the housing through permanent integration methods (overmolding or welding), eliminating the need for separate sealing components like O-rings and clips. This reduces the total number of parts and simplifies the overall device structure while maintaining reliable sealing through the integrated design.
Solution Approach 2:
The harmful elements (O-ring and clip) that contribute to device complexity and potential failure points are extracted from the system. By removing these separate components and integrating the sensor directly into the housing, the design achieves sealing reliability through a simpler, more unified structure.
3Reliability
If the sensor is permanently integrated into the housing, then leakage risk is reduced, but the sensor cannot be easily removed for maintenance
Solution Approach 1:
The sensor and housing are merged into a single integrated component through overmolding or welding, which prevents leakage by eliminating interface gaps where sealing failures could occur. While permanent integration may seem to complicate removal, the design actually simplifies maintenance by allowing the sensor to be removed together with the housing as a single assembly, reducing the number of disassembly steps required.
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 reduces leakage risks and simplifies maintenance by eliminating the need for additional sealing components and provides a more compact design that can utilize previously occupied space for other functions, while maintaining effective temperature regulation.
Implementation Method 1
the temperature sensor, located at the level of the water outlet housing, plays a major role, by allowing the optimum temperature to be maintained at all engine operating speeds
Implementation Method 2
the high temperature of the water coming from the engine causes the movement of a portion of the thermostat, which retracts, causing the outlet to open to the radiator
Implementation Method 3
the welding corresponds to welding by vibration
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for manufacturing a water outlet housing for a cooling circuit of an internal combustion engine, made of plastic, comprising a temperature sensor (12). Furthermore, the method includes a step of final integration of the temperature sensor (12) into the housing (1).