Clamshell Sensor Pad Packaging for Low-Waste Windshield Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current pre-formed silicone sensor pads for vehicle windshields suffer from material waste, high production and handling costs, and inefficiencies due to long curing times, which affect performance and consistency.
Innovation Solution
A packaged sensor pad is formed in situ within a foldable clamshell-type package, minimizing material waste and handling, and using a silicone gel that cures quickly to ensure uniformity and consistency, allowing for easy installation as a single unitary piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-formed silicone sensor pads are die-cut from large sheets and individually packaged, then the pads can be stored and transported separately, but material waste increases and production costs rise
Solution Approach 1:
The patent combines the sensor pad formation and packaging operations into a single integrated process. The silicone material is deposited directly into the final package configuration, eliminating the separate die-cutting and packaging steps that cause material waste. This merging of operations allows the pad to be formed in its final shape and size within the package, achieving both ease of manufacture and material efficiency.
Solution Approach 2:
The package structure is prepared in advance with precise dimensions and configuration before the silicone material is deposited. This preliminary preparation of the package mold allows the silicone to be formed directly into the final product shape without requiring subsequent cutting or trimming operations, thereby eliminating material waste while maintaining individual packaging benefits.
2Ease of operation
If pre-formed sensor pads are handled and removed from packages manually, then installation flexibility is maintained, but handling costs increase and contamination risk rises
Solution Approach 1:
The patent merges the sensor pad with its package structure through direct deposition, creating an integrated unit that simplifies handling. The pad is formed directly within the package boundaries, eliminating the need for separate removal and installation operations. This integration maintains installation flexibility while reducing handling complexity and contamination risk.
Solution Approach 2:
The package structure is designed to be self-contained with the sensor pad already formed within it. The package itself serves as both the container and the mounting structure, eliminating the need for separate handling operations to transfer the pad from packaging to installation location. This self-service approach reduces handling complexity while maintaining ease of operation.
3Manufacturing precision
If silicone gel is used to fill space between windshield and electronic device, then uniform light transmissivity is achieved, but long curing times reduce productivity
Solution Approach 1:
The package structure is prepared in advance with precise dimensions and configuration before the silicone material is deposited. This preliminary preparation allows for optimized material placement and configuration that ensures uniform light transmissivity from the start, eliminating the need for extended curing times to achieve uniformity. The pre-configured mold structure guides the material into the optimal position.
Solution Approach 2:
The patent utilizes controlled deposition parameters to achieve the desired material properties and uniform distribution directly during the formation process. By adjusting deposition conditions, temperature, and pressure parameters during the in-situ formation, the silicone material achieves uniform light transmissivity characteristics without requiring extended curing times, thus maintaining both manufacturing precision and productivity.
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
Reduces material waste and handling costs while ensuring consistent performance and quick curing, enhancing efficiency in aftermarket installations.
Implementation Method 1
using a silicone gel that cures quickly to ensure uniformity and consistency
Data Source
AI summary
A product [11] includes a foldable clamshell-type housing [10] folded to a closed position to contain a pre-formed sensor pad [17] that was formed in situ therein when the housing [10] was in an open position, prior to closing. The housing [10] has an enclosed volume [12] bounded by relatively thin and flexible walls [23, 34], and outwardly extending tabs [18] which facilitate opening. This structure enables the user to easily open the housing [10] to remove the sensor pad [17], a cured silicone composition, by pushing inward on an outer surface of the outer wall [34] of a base section [15] of the housing [10]. This product [11] reduces the amount of manipulation needed to place the sensor pad [17] in a desired position, for example, during installation of a rain sensor system for a vehicle windshield.