Blind Hole Recess for Embedded Sensor in Plastic Components
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Solution Overview
Problem
Existing sensor devices embedded in plastic components, such as ball joints, face challenges in measuring high loads without damaging the thin sensor layers, particularly between a ball socket and joint ball or joint housing, where forces are extremely high.
Innovation Solution
A method involving the creation of blind hole-like recesses in plastic components during injection molding, where a sensor layer with electrically conductive particles is embedded, allowing for protected and reliable measurement of instantaneous loads by changing electrical resistance in response to mechanical loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a thin sensor layer is applied on the component surface to measure loads, then the measurement capability is provided, but the sensor layer is damaged by high loads
Solution Approach 1:
The sensor layer is embedded within a blind hole-like recess in the component, nesting the sensor within the component structure. This protects the sensor layer from direct exposure to high external loads while still allowing it to measure the loads transmitted through the component material.
Solution Approach 2:
The blind hole-like recess acts as an intermediary structure between the external high-load environment and the sensor layer. The recess shields the sensor from direct mechanical damage while the component material itself transmits the load information to the sensor for measurement.
2Ease of manufacture
If the sensor layer is applied on an open surface for easy access, then the installation is simple, but the sensor is exposed to damage and wear
Solution Approach 1:
The sensor layer is nested within the blind hole-like recess, which is formed during the injection-molding process. This integration into the component structure during manufacturing provides automatic protection while maintaining ease of production.
Solution Approach 2:
The blind hole-like recess is formed during the injection-molding process before the component is assembled or put into service. This preliminary creation of the protective structure ensures the sensor is protected from the outset without adding extra manufacturing steps.
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 enables durable and accurate measurement of forces and force components on plastic components, protecting the sensor layer from damage and ensuring reliable data over the component's lifetime, with the ability to measure various types of loads like shear, compression, and tensile forces.
Implementation Method 1
the sensor layer enables electrical resistance measurements to be carried out. From the electrical resistance measurements at the sensor device or sensor layer, the instantaneous load, in particular a force or force component acting on the component, can be determined.
Data Source
AI summary
A method for producing a sensor device (2) for the measurement of an instantaneous load on a component (1, 15), in which the component (1, 15) is made of plastic, in which a sensor layer (3) is arranged in the component (1, 15). The sensor layer (3) is formed of a carrier material with electrically conductive particles embedded therein. To be able to measure or determine loads and/or forces in the component (1, 15) in a better an/or more reliable way, the method includes forming at least one blind hole-like recess (4) in the component (1, 15) to receive the sensor layer (3).