Wire Spring Sensor Housing Closure for Thermal Expansion Sealing
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Solution Overview
Problem
Conventional fasteners used to secure sensor housings on vehicles fail to maintain a secure coupling under extreme temperature variations due to differing material expansion and contraction rates, leading to loose fits and compromised seals.
Innovation Solution
A wire spring closure device using stainless steel wire with a spring portion that biases upper and lower housing portions together, maintaining a secure and removable coupling despite temperature extremes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fasteners (screws, clips, glue) are used to secure housing portions together, then the housing can be assembled and secured, but the fasteners become compromised under extreme temperature variations due to different material expansion and contraction rates
Solution Approach 1:
The closure device utilizes the elastic properties of spring steel wire, changing the mechanical parameter of the fastener from rigid to flexible. The wire is formed into a spring configuration that can elastically deform to accommodate thermal expansion and contraction of the housing portions while maintaining securing force across extreme temperature ranges from -50°C to +85°C
Solution Approach 2:
The closure device transitions from a static fastening mechanism to a dynamic one where the spring portions continuously adapt to dimensional changes in the housing. The elastic deformation of the wire allows the closure to maintain optimal securing pressure despite temperature-induced dimensional variations in the plastic and metal housing components
2Strength
If mechanical fasteners are used to hold housing portions together, then the housing can be secured, but the fasteners contract and expand with temperature changes causing loose fits
Solution Approach 1:
The closure device changes the mechanical parameter of the fastener from rigid to flexible by forming the fastener from spring steel wire into a spring configuration. This elastic structure can deform to accommodate thermal expansion and contraction while maintaining securing force, preventing loose fits that occur with conventional rigid mechanical fasteners under temperature variations
3Adaptability or versatility
If housing portions are made of different materials (plastic and metal), then the housing can be constructed with appropriate material properties, but the different thermal expansion rates cause the coupling to become compromised
Solution Approach 1:
The closure device changes the mechanical parameter of the fastener from rigid to flexible by using spring steel wire that can elastically deform. This allows the fastener to accommodate the different thermal expansion rates of plastic and metal housing portions, maintaining coupling security despite the material incompatibility caused by differential thermal expansion
Solution Approach 2:
The closure device itself is formed as a composite structure combining spring steel wire for elastic properties with plastic retaining bars for engagement. This composite construction allows the fastener to exhibit both the flexibility needed to accommodate thermal expansion differences and the structural integrity required to maintain secure coupling between dissimilar housing materials
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 wire spring closure device ensures a secure, airtight, and watertight seal across temperature ranges by providing sufficient spring tension to accommodate expansion and contraction, facilitating easy servicing.
Implementation Method 1
a spring portion (214) coupled to the first portion and to the second portion, where the spring portion is configured to pull the first retaining bar and the second retaining bar towards each other when stretched
Implementation Method 2
Contraction and expansion of the sensor housing can deteriorate the effectiveness of fasteners used to hold the sensor housing together. This problem can be exacerbated when the fasteners used to hold the sensor housing together are of a different material than the housing itself, and therefore have different expansion and contraction properties.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A sensor housing system comprises an upper housing portion (302), a lower housing portion (304), and a wire spring closure device having a closure feature configured to secure the upper housing portion to the lower housing portion. The wire spring closure device comprises an upper portion (210) comprising an upper retaining bar (212), and a spring portion (214) coupled to the upper portion. The wire spring closure device also comprises a lower portion (206) coupled to the spring portion and comprising a lower retaining bar (208).