Hollow Insulator Blocking Member for Resin Intrusion Prevention

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Solution Overview

Problem

Conventional object detection sensors for electric door opening and closing systems face issues with resin material entering the hollow insulator during terminal molding, leading to defective products and electrical short-circuiting of electrode wires.

Innovation Solution

Incorporating a blocking member at the longitudinal end of the hollow insulator to prevent resin material from entering the insulator during terminal molding, and using ultraviolet curing resin for the blocking member to facilitate easy handling and effective blocking of resin flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If high pressure is applied to fill melted resin into the mold during terminal molding, then the terminal molded member is properly formed, but the melted resin enters the hollow insulator from between the spacer and bore inner surface, causing defects

Engineering Contradiction:

Improveterminal molded member formationVSAvoidresin material intrusion into hollow insulator

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

A blocking member is preliminarily installed at the longitudinal end of the hollow insulator before the injection molding process. This blocking member proactively prevents the melted resin from entering the hollow insulator during the high-pressure injection process, thereby eliminating the harmful effect of resin intrusion while allowing the terminal molded member to be properly formed.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the hollow insulator is left open during terminal molding, then the manufacturing process is simpler, but resin material can enter and cause electrical short-circuiting of electrode wires

Engineering Contradiction:

Improvemolding process simplicityVSAvoidelectrical insulation integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The blocking member serves as an intermediary element that is temporarily installed at the hollow insulator's opening. It mediates between the need for an open structure during manufacturing and the requirement for resin containment, allowing the molding process to proceed while preventing resin intrusion that would compromise electrical insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a blocking member is added to prevent resin intrusion, then product reliability is improved, but device complexity increases

Engineering Contradiction:

Improveprevention of resin intrusionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The blocking member is designed as a temporary component that is discarded after serving its protective function during injection molding. Once the terminal molded member is formed and the mold is opened, the blocking member is removed and discarded, leaving no permanent additional components in the final product assembly.

Inventive Principle:

Principle #34Discarding and recovering

4Reliability

If a rigid blocking member is used to prevent resin entry, then blocking effectiveness is improved, but handling and installation become more difficult

Engineering Contradiction:

Improveresin flow blocking capabilityVSAvoidhandling and installation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The blocking member is designed with specific dimensional parameters that allow it to effectively block resin flow while maintaining ease of handling. The blocking member's size and shape are optimized to fit within the hollow insulator's bore, providing sufficient blocking capability without being overly large or complex for manual installation.

Inventive Principle:

Principle #35Parameter changes

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 solution reduces the occurrence of defective products by preventing resin intrusion into the hollow insulator, minimizes electrical short-circuiting, and simplifies the manufacturing process by using a flowable resin that hardens in place, ensuring reliable object detection sensor functionality.

Implementation Method 1

The blocking member blocks entrance of the terminal molding resin material into the hollow insulator

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

using ultraviolet curing resin for the blocking member to facilitate easy handling and effective blocking of resin flow

Methodology Applied

Scientific EffectUltraviolet curing: Photopolymerisation

Data Source

PatentUS9059712B2Object detection sensor and method for producing the same

Publication Date: 2015.06.16 DENSO CORP

AI summary

An object detection sensor includes a hollow insulator, a plurality of electrode wires, a terminal molded member, and a blocking member. The hollow insulator includes a longitudinal end. The electrode wires are arranged in the hollow insulator with the electrode wires spaced apart from each other. Each electrode wire includes a drawn-out portion that is drawn out of the hollow insulator from the longitudinal end of the hollow insulator. The terminal molded member is formed from an insulative terminal molding resin material. The drawn-out portions are embedded in the terminal molded member. The blocking member, which is arranged at the longitudinal end of the hollow insulator, blocks entrance of the terminal molding resin material into the hollow insulator.