One-Piece Ejector Element for Belt Buckle Sensor
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Solution Overview
Problem
Existing belt buckle sensor systems require complex and costly production methods for the ejector element with a trigger, which can lead to increased time and costs in manufacturing, and may not ensure safe and reliable operation.
Innovation Solution
A one-piece ejector element with a trigger blade connected to the ejector body via a multi-component injection-molding process, where the trigger blade can be made of magnetic and/or metallic material and the ejector body from plastic, eliminating the need for additional connection methods like rivets or adhesive bonds, and allowing for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-step production methods (riveting, adhesive bonding) are used to connect the trigger blade and ejector body, then the connection strength may be improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent combines the trigger blade and ejector body into a single integrated component produced by injection molding. This merging eliminates the need for separate connection steps (riveting, adhesive bonding) while maintaining structural integrity. The trigger blade is formed as an integral part of the ejector body through the injection molding process, resolving the contradiction by achieving both connection strength and manufacturing simplicity.
Solution Approach 2:
The patent employs composite material construction where the trigger blade is made from a magnetic material (such as ferrite or magnetically conductive plastic) and the ejector body from suitable molding material. This composite approach allows the integrated component to maintain both mechanical strength and magnetic functionality for sensor interaction, while being produced as a single piece through injection molding.
2Manufacturing precision
If traditional multi-step production methods are used, then assembly precision may be improved, but the productivity decreases
Solution Approach 1:
The injection molding process incorporates preliminary action by forming the trigger blade and ejector body as a pre-assembled integrated component. The precise geometric relationships and positioning features are built into the mold cavity itself, ensuring assembly precision is achieved during the molding process rather than requiring subsequent assembly steps. This preliminary formation of the complete structure significantly increases productivity.
3Adaptability or versatility
If separate components are used and connected by additional methods, then the adaptability may be improved, but the device complexity increases
Solution Approach 1:
The integrated ejector element serves multiple functions: the ejector body provides the mechanical ejection function, while the integrated trigger blade provides both the mechanical triggering function and magnetic interaction with the sensor. This multi-functionality in a single component reduces device complexity while maintaining the adaptability needed for different sensor types (Hall sensors, inductive sensors) through material selection.
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 enables a safer, more reliable, and cost-effective production of the ejector element, reducing production time and complexity while ensuring a secure connection between the trigger blade and ejector body, facilitating efficient detection of the belt buckle's locking state.
Implementation Method 1
A button on the housing of the belt buckle is usually used to open the belt. In modern motor vehicles, a sensor is installed in the belt buckle and, together with a sensor in the seat, determines whether someone is occupying the seat and whether that person has fastened their seatbelt.
Implementation Method 2
A plurality of technologies for latch detection are commercially available, for example by means of a Hall sensor. Hall sensors consist of very thin crystalline doped semiconductor layers which generally have four electrodes to the side.
Data Source
AI summary
An ejector element with a trigger for a belt buckle sensor includes a plate-shaped ejector body and a trigger blade of a magnetic and/or metallic material for producing a change in a magnetic field of a Hall sensor or an inductive sensor. The ejector element is distinguished by the fact that the trigger blade is connected in one piece to the ejector body, wherein the one-piece connection between the trigger blade and the ejector body is produced by an injection-molding process.