Compact Seating Sensor Layout for Lower Material Use
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Solution Overview
Problem
Existing seating sensors are costly to manufacture due to increased material requirements from wires extending away from the sensor area, leading to enlarged sensor sizes and higher production costs.
Innovation Solution
A seating sensor design with a film-like base table featuring a sensor portion and a connector portion, where conductors are integrated within a minimum rectangular area, reducing the sensor's size and allowing more sensors to be produced from a single material sheet, and utilizing OR and AND circuits to prevent false detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires extend to a location away from the pressure-sensitive sensors and connector, then the seating sensor can be connected to external systems, but the sensor size increases and material cost increases
Solution Approach 1:
The patent merges the connector portion with the sensor portions by arranging the connector within the minimum rectangular area containing the sensor portions. The base table integrates both functional areas, eliminating the need for separate wire extensions to external locations. This consolidation reduces the overall sensor size and minimizes material usage while maintaining electrical connectivity functionality.
Solution Approach 2:
The patent repositions the connector from an external location (requiring wire extensions) to an internal location within the sensor assembly's footprint. By utilizing the vertical integration on the base table and arranging components within the minimum rectangular area, the design transitions from a distributed layout to a compact integrated layout, reducing the area occupied by wire extensions.
2Ease of manufacture
If wires extend away from the sensor area to connect sensor portions and connector, then electrical connectivity is achieved, but material usage increases leading to higher costs
Solution Approach 1:
The base table integrates the connector portion with the sensor portions within the same minimum rectangular area. This merging eliminates the need for separate wire extensions and reduces the overall material quantity required for the base table, while maintaining all necessary electrical connectivity functions between sensors and the connector.
3Area of stationary object
If the connector is arranged between pressure-sensitive sensors with wires extending away, then connectivity is established, but the sensor requires more space for wire routing
Solution Approach 1:
The connector is merged with the sensor portions by positioning it within the minimum rectangular area containing all sensor elements. This integration eliminates the need for complex wire routing to external locations, as all connections are established within the compact sensor assembly footprint, simplifying both installation and maintenance.
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
The design enables inexpensive manufacturing by minimizing material usage and ensuring accurate detection of occupant seating through the integration of conductors within the sensor area and the use of OR and AND circuits.
Implementation Method 1
a sensor portion having three or more switches conducted by a pressing force by the seating of the person
Data Source
AI summary
The present invention relates to a seating sensor 100. the base table 10 includes a first part 11 provided with the sensor portion 1 and a second part 12 provided with the connector portion 2, and the second part 12 is arranged within a minimum rectangular area S1 containing the first part 11.