Integrally Molded Sensor Mounting Sections on Vehicle Fairings
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Solution Overview
Problem
The existing methods for attaching sensors to vehicle trim components require numerous site-specific sensor mounts, leading to high manufacturing and logistical efforts, and there is a risk of incorrect installation, which can result in sensor detachment due to mismatched geometry and reduced pull-off forces.
Innovation Solution
The use of integrally molded or attached fastening sections with reduced wall thickness on the trim components, eliminating the need for geometry-specific joining flanges, and incorporating stabilizing means such as adhesives or form-fitting elements to ensure secure attachment and alignment of sensors regardless of the trim component's curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If site-specific sensor mounts with joining flanges are used for each sensor location, then the sensors can be attached to trim components with specific geometries and curvatures, but the manufacturing and logistical effort increases significantly and the risk of incorrect installation rises
Solution Approach 1:
The patent applies universality by replacing numerous site-specific sensor mounts with a single universal sensor mount design. The universal mounting element can be used at all sensor locations regardless of the trim component's geometry or curvature, eliminating the need for location-specific variations while maintaining reliable attachment through the stabilizing agent and form-fitting connection.
Solution Approach 2:
The patent segments the sensor mounting system into two independent parts: a universal mounting element and a stabilizing agent. This segmentation allows the mounting element to remain geometry-independent while the stabilizing agent adapts to local conditions, resolving the contradiction between universal design and location-specific requirements.
2Strength
If joining flanges are adapted to match the geometry of the wall at each sensor location, then the pull-off forces are sufficient, but the manufacturing complexity and logistical effort increase
Solution Approach 1:
The patent replaces the mechanical geometry-matching system (joining flanges adapted to wall curvature) with a chemical-biological system (stabilizing agent). Instead of relying on mechanical interlocking through geometry adaptation, the solution uses adhesive bonding that can accommodate various geometries while maintaining sufficient pull-off force.
Solution Approach 2:
The patent changes the attachment mechanism from mechanical (geometry-dependent) to chemical (adhesive bonding). This parameter change allows the same mounting element to achieve sufficient strength across different geometries without requiring manufacturing adaptations for each location.
3Shape
If the wall thickness is reduced in the attachment sections, then sink marks and visual disturbances are avoided, but the structural stability of the fastening sections decreases
Solution Approach 1:
The patent introduces a stabilizing agent as an intermediary between the reduced-thickness mounting element and the trim component. This mediator compensates for the reduced structural stability of the thin-walled mounting element by providing adhesive bonding, allowing the mounting element to maintain both visual appearance (no sink marks) and structural stability.
Solution Approach 2:
The patent creates a composite attachment system combining the plastic mounting element with a stabilizing agent (adhesive). This composite structure allows the thin-walled mounting element to achieve the required stability through the adhesive bonding, eliminating the need for thicker walls while maintaining both appearance and strength.
4Shape
If a reduced wall thickness is used in attachment sections, then sink marks are prevented, but additional stabilizing means are required to ensure adequate attachment strength
Solution Approach 1:
The patent merges the stabilizing function into the sensor mounting process itself by applying the stabilizing agent directly at the sensor location during assembly. This combines multiple functions (mounting and stabilizing) into a single integrated process, reducing overall system complexity despite the reduced wall thickness.
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a fairing component (10) for a vehicle, comprising a wall (12), one or more mounting sections (14) for aligning and attaching a sensor to the fairing component (10), wherein the mounting sections (14) are formed integrally with the wall (12) or integrally molded onto the wall (12), and have a reduced wall thickness (18) at least in a transition area (16) to the wall (12). The invention further relates to a fairing component (10) for a vehicle, comprising a wall (12), and one or more sensor receptacles (24) for receiving a sensor, wherein the sensor receptacle (24) is formed integrally with the wall (12) or integrally molded onto the wall (12).Furthermore, the invention relates to a vehicle with such a fairing component and to a method for aligning and attaching a sensor and/or a sensor receptacle (24) to a fairing component (10) of a vehicle.