Integrated Air Flow Sensor Housing Design
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Solution Overview
Problem
Conventional air flow measuring devices require multiple components and complex assembly processes, leading to increased manufacturing costs and device size.
Innovation Solution
An air flow measuring device with a resin housing that integrates a sensor assembly, thermistor, and end terminals, where external connection terminals function as both sensor and thermistor terminals, reducing component count and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (sensor assembly, thermistor, end terminals) are used in conventional air flow measuring devices, then functional reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the sensor assembly, thermistor, and end terminals into a single integrated housing structure. The housing simultaneously serves as the structural enclosure, the sensor mounting platform, the thermistor mounting structure, and the electrical connection interface, eliminating the need for separate components and reducing assembly steps.
Solution Approach 2:
The housing is designed as a multi-functional component that performs multiple roles: structural support, sensor mounting, thermistor mounting, and electrical connection. This universal design allows a single component to replace what were previously multiple separate parts, simplifying the overall device architecture.
2Reliability
If multiple separate components are assembled and joined together, then functional reliability is improved, but manufacturing cost increases
Solution Approach 1:
By merging the sensor assembly, thermistor, and end terminals into a single integrated housing, the patent eliminates multiple assembly and joining operations. This reduces manufacturing steps, lowers labor costs, and simplifies the production process while maintaining all necessary functions through the integrated design.
3Reliability
If multiple separate components are used, then functional reliability is improved, but device size increases
Solution Approach 1:
The integration of multiple components into a single housing structure eliminates the space required for separate component housings and the gaps necessary for assembly. This consolidation reduces the overall device volume while maintaining all functional elements within the integrated structure.
Data Source
AI summary
A sensor assembly includes a sensor portion and a sensor circuit, which are integrated with each other and configured to measure an air flow quantity. A thermistor is configured to measure an air temperature. A metal plate includes a grounding end terminal. One lead wire of the thermistor is joined electrically with the grounding end terminal. The sensor circuit is disposed on the metal plate. The sensor circuit is entirely overlapped with the plate shape portion in a direction perpendicular to the metal plate.