Aluminum Etching Sensor for Automotive Passenger Detection
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Solution Overview
Problem
Existing passenger detecting sensors in automobiles are costly due to the use of expensive silver paste for conductive members, which increases operational costs while maintaining performance standards.
Innovation Solution
The use of aluminum patterns formed through an etching method on flexible panels, combined with carbon paste to prevent oxidation, and bonded with a spacing mechanism to detect passenger seating, reducing material costs and enhancing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silver paste is used for conductive members, then electrical conductivity is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from silver paste to aluminum pattern with carbon paste coating. This substitution maintains adequate electrical conductivity while dramatically reducing material cost, as aluminum is significantly cheaper than silver. The carbon paste coating compensates for aluminum's lower conductivity and prevents oxidation
Solution Approach 2:
The patent uses a composite structure combining aluminum pattern (for base conductivity and low cost) with carbon paste coating (for oxidation protection and conductivity enhancement). This composite approach achieves performance接近 to pure silver paste at a fraction of the cost
2Ease of manufacture
If aluminum is used instead of silver paste, then manufacturing cost decreases, but oxidation resistance worsens
Solution Approach 1:
The patent introduces carbon paste as an intermediary protective layer on the aluminum surface. This carbon coating acts as a barrier against oxidation while maintaining electrical conductivity, solving the oxidation resistance problem of aluminum without sacrificing the cost advantage
Solution Approach 2:
The composite structure of aluminum pattern plus carbon paste coating provides both cost effectiveness and oxidation resistance. The aluminum provides the base conductivity and low cost, while the carbon paste layer provides oxidation protection and enhances surface conductivity
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 decreases material costs by using aluminum and improves performance by maintaining low output resistance, while simplifying the manufacturing process through the aluminum etching method.
Implementation Method 1
forming an aluminum pattern by corroding the aluminum
Implementation Method 2
printing a carbon paste on the aluminum pattern
Data Source
AI summary
The present invention relates to a passenger detecting sensor which is installed in a seat to detect whether a passenger is seated on a seat, and a method of manufacturing the same. A method of manufacturing a passenger detecting sensor includes printing corrosion preventive ink on aluminum bonded on a flexible panel in accordance with a pattern; forming an aluminum pattern by corroding the aluminum; cleaning the corrosion preventive ink on the aluminum pattern; and printing a carbon paste on the aluminum pattern.