Segmented Collision Sensor Housing for Impact Protection
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Solution Overview
Problem
Existing automotive air bag control systems face challenges in providing a low-cost, effective housing for collision sensors that protects them from physical impact and chemical exposure while maintaining functionality.
Innovation Solution
A collision sensor housing comprising a rigid part with a protective cavity and a flexible part, where the rigid part is attached to a vehicle surface with a wing configuration to house the circuit board, and the flexible part seals the cavity to prevent damage and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid housing is used to protect the collision sensor, then protection from physical impact is improved, but cost increases
Solution Approach 1:
The housing is divided into two distinct parts: a rigid portion providing structural strength and impact protection, and a flexible portion providing sealing and chemical resistance. This segmentation allows each part to be optimized for its specific function while keeping overall costs lower than a fully rigid housing would require.
Solution Approach 2:
The housing combines rigid and flexible materials with different properties into a unified structure. The rigid part provides mechanical strength while the flexible part provides sealing and chemical resistance, creating a composite housing that achieves superior protection at lower cost than a fully rigid alternative.
2Strength
If a fully rigid housing is used, then protection from chemical exposure is reduced, but structural strength is improved
Solution Approach 1:
Different portions of the housing have different material properties tailored to their specific functional requirements. The rigid portion provides structural strength where needed, while the flexible portion provides chemical resistance and sealing where it contacts the environment and sensor components.
Solution Approach 2:
The housing uses a composite construction with rigid and flexible materials, each providing specific protective qualities. The flexible portion specifically addresses chemical exposure protection while the rigid portion maintains structural integrity.
3Ease of manufacture
If the circuit board is exposed, then manufacturing simplicity is improved, but protection from damage is reduced
Solution Approach 1:
The circuit board is nested within the protective cavity formed by the rigid and flexible housing portions. This nesting provides protection without requiring complex external mounting structures, maintaining manufacturing simplicity while significantly improving damage protection.
Solution Approach 2:
The housing is segmented to create a protective cavity that houses the circuit board. This segmentation allows the circuit board to be protected within the housing structure without requiring the entire housing to be complex, maintaining ease of manufacture.
4Reliability
If a protective cavity is created, then sensor protection is improved, but device complexity increases
Solution Approach 1:
The protective cavity is created through segmentation of the housing into rigid and flexible portions rather than through complex internal structures. This segmentation approach provides effective protection while keeping the overall housing structure relatively simple and easy to manufacture.
Data Source
AI summary
A collision sensor module configured to be attached to a surface of a vehicle. The module includes a collision sensor circuit board configured to detect acceleration indicative of a vehicle collision event. The exterior of the module is defined by a housing that includes a rigid part and a flexible part. The rigid part is configured to define a wing portion for attaching the rigid part to the surface, provide an underside surface of the rigid part to couple the collision sensor circuit board to the surface in a manner effective for the circuit board to detect when the vehicle is involved in a collision event. The flexible part is configured to sealingly contact the rigid part and the collision sensor circuit board in a manner effective to seal the protective cavity when the rigid part is attached to the surface and thereby protect the collision sensor circuit board.