Air Flow Sensor Housing Assembly Process Simplification
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Solution Overview
Problem
The manufacturing process of conventional air flow measuring devices is complicated due to the need for multiple insert-molding steps, which increases costs and complexity.
Innovation Solution
The air flow measuring device employs an assembly process where the conduction member is held by a primarily shaped product defining the bypass flow passage, and then inserted into a die for injection-molding, eliminating the need for a 'molded product with a terminal' through insert-molding, thereby simplifying the process and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple insert-molding steps are used to provide the molded product with terminal and housing, then the conduction member can be integrated with the housing, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent combines the conduction member and housing into a single integrated component through a one-step insert-molding process. The conduction member is first formed as a preliminary shaped product, then the housing material is molded around it in the same die without removing the conduction member. This merging eliminates the need for separate assembly steps and multiple insert-molding operations, directly resolving the technical contradiction by simplifying the manufacturing process while maintaining integration.
Solution Approach 2:
The conduction member is formed as a preliminary shaped product before the final housing molding process. This preliminary formation allows the conduction member to be prepared in advance and then integrated into the housing in a single subsequent step, rather than requiring multiple separate molding operations. This preliminary action reduces the overall manufacturing complexity while achieving the desired integration.
2Device complexity
If the conduction member is directly set in the die as insertion item, then the process can be simplified, but it becomes cumbersome and difficult to handle
Solution Approach 1:
The conduction member is formed as a preliminary shaped product with specific geometric features that facilitate easy handling and positioning during the molding process. This preliminary shaping is done in advance, creating a component that is both simple to manufacture and easy to manipulate in the die, thus resolving the contradiction between process simplicity and ease of operation.
3Device complexity
If the conduction member is held by a primarily shaped product and then injection-molded, then manufacturing complexity is reduced, but heat deformation and positional changes may occur
Solution Approach 1:
The conduction member is formed as a preliminary shaped product with built-in positioning features that ensure accurate location during the injection-molding process. These pre-formed geometric features act as locators that guide the conduction member into the correct position, preventing heat deformation and positional changes during molding, thus maintaining manufacturing precision while simplifying the overall process.
Solution Approach 2:
The preliminary shaped product acts as an intermediary between the conduction member and the final housing. It provides a stable holding structure that maintains the conduction member's position during the injection-molding process, preventing heat deformation and ensuring positional accuracy. This intermediary structure resolves the contradiction by enabling process simplification without sacrificing precision.
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 approach reduces manufacturing complexity and costs by eliminating at least one insert-molding step, while ensuring accurate and stable attachment of the conduction member, and limiting heat deformation and positional changes over time, enhancing the device's reliability in high-temperature environments.
Implementation Method 1
a sensor that is accommodated in the bypass flow passage to produce the electrical signal as a result of a heat transfer between the sensor and the taken-in air
Implementation Method 2
a secondary molded part is injection-molded in the die
Data Source
AI summary
An air flow measuring device includes a housing, a sensor, and a conduction member. The housing defines a bypass flow passage through which taken-in air passes. The sensor is accommodated in the bypass passage and produces an electrical signal as a result of heat transfer between taken-in air and the sensor. The conduction member includes first and second terminals. The first terminal outputs the electrical signal produced by the sensor to outside. The second terminal supplies electric power to the sensor. The housing is provided through an assembly process and a molding process. In the assembly process, the conduction member is held by a primarily shaped product defining the bypass passage to provide an assembly. In the molding process, the assembly, with the conduction member held by the primarily shaped product, is inserted into a predetermined die and a secondary molded part is injection-molded in the die.