Door Lock Sensor Assembly With Resin-Sealed Terminal Connections
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Solution Overview
Problem
Existing door lock devices for vehicles face challenges in maintaining waterproofness, particularly when exposed to driving rain or high-pressure water washing, which can lead to short circuits at the sensor's terminal connections with electric wires.
Innovation Solution
A sensor assembly is introduced that includes a connector to hold connection conductors, a sensor base to hold the sensor, and a waterproofing material made from light curing resin to cover the connecting portions between the sensor's terminal portions and electric wires, enhancing the waterproofness without compromising productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal portions of the sensor are provided above the draining portion to prevent water from staying below them, then water can be drained effectively during normal rain, but the terminal portions remain exposed and vulnerable to water gushing during driving rain or high-pressure washing
Solution Approach 1:
A waterproofing member made of flexible waterproofing material is provided to cover the terminal portions of the sensor. This flexible shell structure effectively seals the terminal portions, preventing water from entering during driving rain or high-pressure washing, while maintaining the drainage function during normal rain conditions.
Solution Approach 2:
The waterproofing member acts as an intermediary element between the terminal portions and the external environment. It selectively allows water to pass during normal rain (maintaining drainage) while blocking water during high-pressure conditions (preventing intrusion), thus mediating the interaction between water and terminal portions.
2Productivity
If the terminal portions are exposed above the draining portion for effective drainage, then water can flow away during normal rain, but the connecting portions remain vulnerable to short circuits under extreme water exposure
Solution Approach 1:
The waterproofing member forms a flexible shell that covers the terminal portions while allowing water to flow around or through it during normal drainage conditions. During high-pressure water exposure, the flexible material conformally seals the terminal portions, preventing water intrusion and short circuits while maintaining drainage efficiency.
3Reliability
If additional waterproofing structures are added to protect the terminal portions, then waterproofness is improved, but the complexity of the door lock device increases
Solution Approach 1:
Instead of adding complex rigid waterproofing structures, the invention uses a simple flexible waterproofing member that can be easily installed over the terminal portions. This flexible shell provides effective waterproofing without significantly increasing device complexity, as it can be a simple wrap-around or cap structure.
Solution Approach 2:
The waterproofing member serves as a simple intermediary component that bridges the gap between the terminal portions and the external environment. It provides waterproofing functionality without requiring complex integration into the existing door lock device structure, thus minimizing increases in device complexity.
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 solution effectively prevents short circuits and ensures the reliability of the door lock device by enhancing the waterproofness of the connecting portions between the sensor and electric wires, even under conditions of driving rain or high-pressure water exposure.
Implementation Method 1
a waterproofing material made from a light curing resin and configured to cover connecting portions together with the sensor base
Data Source
AI summary
The present invention is a sensor assembly that is used in a door lock device provided with a latch, a ratchet, a drive unit that drives the ratchet and releases the engagement of the ratchet and the latch, and a case that accommodates the drive unit, the sensor assembly being provided with a sensor that detects the action of the ratchet when the engagement of the ratchet and the latch is released, wherein the sensor assembly is provided with: a connector that holds connection conductors electrically connected to the sensor, and is attached to the case; a sensor base that holds the sensor; a plurality of electric wires that connect the plurality of connection conductors and a plurality of terminal portions of the sensor; and a waterproofing material that comprises a photo-curing resin for covering, along with the sensor base, connecting portions of the terminal portions and the electric wires.