Automotive Door Sensor Protector with Oblique Redirection
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Solution Overview
Problem
Existing protectors with sensors for automobiles are prone to damage and malfunction due to convex objects, such as automobile keys, abutting the thin parts of the hollow sensor components, leading to cracks and improper door or sun roof operation.
Innovation Solution
The design features a hollow part with oblique sides on both the inner and outer cabin sides, inclined at stable angles to direct convex objects towards the top end, preventing impact on thin parts and ensuring the sensor function remains intact by integrating the installation base member, conductive parts, and core wires for enhanced protection and detection range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the hollow part is made with thin walls to reduce material usage and cost, then manufacturing cost is reduced, but the part becomes vulnerable to damage from convex objects like automobile keys
Solution Approach 1:
The hollow part is designed with asymmetric wall thickness distribution: thin-walled sections in areas not prone to impact and thick-walled sections in areas vulnerable to convex objects. This asymmetric structure optimizes material usage while providing targeted protection where needed most.
Solution Approach 2:
The protector is installed on the sliding door before the door closes, creating a preliminary protective barrier. This preliminary positioning allows the protector to intercept and redirect convex objects before they can damage the sensor or other critical components.
2Strength
If the hollow part is made with thick walls to prevent damage from convex objects, then strength and durability are improved, but material usage and manufacturing cost increase
Solution Approach 1:
Different sections of the hollow part have different wall thicknesses tailored to their specific functional requirements and exposure risks. The thick-walled sections are strategically placed only where convex objects are likely to impact, while other sections maintain thinner walls to reduce overall material consumption.
3Ease of manufacture
If the hollow part has a simple shape to ease manufacturing, then manufacturing complexity is reduced, but it cannot effectively redirect convex objects away from thin parts
Solution Approach 1:
The hollow part incorporates curved surfaces and rounded transitions instead of sharp angles or flat surfaces. These curved geometries naturally guide convex objects along smooth paths away from vulnerable thin-walled sections, reducing stress concentration points while remaining manufacturable using standard molding techniques.
4Reliability
If the hollow part has a complex shape to redirect convex objects effectively, then sensor protection is improved, but manufacturing complexity increases
Solution Approach 1:
The complex redirection geometry is achieved through smooth curved surfaces that can be formed using conventional injection molding or similar manufacturing processes. The curved transitions guide objects away from thin parts without requiring multi-step manufacturing or assembly operations.
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
This configuration effectively prevents damages and cracks on the hollow part, maintains sensor functionality, and ensures smooth operation of doors and sun roofs by redirecting convex objects away from vulnerable areas, thus enhancing the durability and reliability of the sensor system.
Implementation Method 1
a sensor (pressure sensitive sensor) 80 which outputs a corresponding electric signal upon detecting the object such as a part of human bodies
Implementation Method 2
two core wires (electrode wires) 31, 32 extending in an upper and lower direction (longitudinal direction) embedded in rubber like elastic bodies (conductive parts) 34, 35 having conductivity
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A protector with a sensor comprises: a hollow part; and an installation base member formed on the hollow part. In the hollow part, a plurality of conductive parts have core wires embedded therein respectively and a space is positioned between the plurality of conductive parts. The plurality of conductive parts include: a conductive part on a lower part of the hollow part as a side of the installation base member; and a conductive part on an upper part of the hollow part separated from the side of the installation base member by the space. The hollow part includes: an oblique side on an inner-cabin side extending from an inner-cabin side end connected with the installation base member to a tip; and an oblique side on an outer-cabin side extending from an outer-cabin side end connected with the installation base member to the tip.