Cable Sensor Curved Cylinder Resin Molding
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Solution Overview
Problem
Conventional cables with sensors experience voids in the resin member when the wire is bent, leading to reduced strength and waterproofing, which can compromise the durability of the cable.
Innovation Solution
A cable design featuring a curved cylinder section made of molded resin with a circular cross-section, holding the electrically insulated wires in a curved state, which maintains a controlled temperature distribution during resin molding, preventing voids and ensuring the wires are securely positioned.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wire is drawn from the resin member perpendicularly to the axis of the Hall IC (bending the wire within the resin member), then the wire does not interfere with other parts mounted on the vehicle body, but voids occur in the resin member during molding, reducing strength and waterproof properties
Solution Approach 1:
The patent introduces a curved cylinder section with a circular cross-section to hold the wires in a curved state, transitioning the wire arrangement from a planar 2D layout to a three-dimensional curved configuration. This dimensional change allows the wires to be routed perpendicular to the Hall IC axis without creating voids in the resin member, as the circular cross-section provides uniform support and prevents resin accumulation issues.
2Ease of manufacture
If the wire is drawn from the resin member in the axial direction of the Hall IC, then the molding process is simpler, but the wire interferes with other parts such as suspension arms and brake dust covers
Solution Approach 1:
The curved cylinder section enables the wires to exit the resin member in a direction perpendicular to the Hall IC axis by utilizing a three-dimensional curved path instead of a straight axial route. This spatial reconfiguration allows the wiring to clear other vehicle components while maintaining manufacturability through the molded resin structure.
3Ease of operation
If the curved cylinder section holds wires in a curved state with non-uniform distribution, then the wires can be routed perpendicular to the Hall IC axis, but voids still occur in the resin member
Solution Approach 1:
The curved cylinder section with circular cross-section provides a three-dimensional curved space that naturally distributes wires uniformly along the curved path. The circular geometry ensures equal spacing and support for all wires, preventing resin voids while maintaining the perpendicular wire routing configuration.
Data Source
AI summary
A cable with a sensor includes electrically insulated wires, a sheath for covering the electrically insulated wires together, a sensor, and a housing for sealing one end of the sheath, while receiving at least a portion of the sensor. The housing includes a receiving portion for receiving the at least portion of the sensor, a lead out portion for the sheath being drawn therefrom, and a curved cylinder section having a circular cross section. The curved cylinder section is provided between the receiving portion and the lead out portion, to hold the electrically insulated wires. The curved cylinder section is made of a molded resin formed in a circular cross sectional shape at right angles to a direction of extending of the electrically insulated wires. The electrically insulated wires are held in the middle of the circular cross section of the curved cylinder section.