Intraoral Sensor Cable Welding for Airtight Package Integrity
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Solution Overview
Problem
Intraoral sensors face issues with airtightness due to stress on the bonding material securing the cable to the sensor body, leading to potential damage and reduced sealing effectiveness during disinfection processes.
Innovation Solution
A method involving the use of resin welding to secure the signal cable jacket to the cable connection unit, ensuring the gap between the jacket and connection unit is sealed, thereby preventing damage from stress and enhancing airtightness within the sensor package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable is secured to the sensor body with bonding material, then the cable connection is achieved, but the airtightness is compromised due to stress damage
Solution Approach 1:
The patent replaces the mechanical bonding system with a welding system. The cable jacket and cable connection unit are directly welded together through heat fusion, eliminating the bonding material layer that was susceptible to stress damage. This substitution of bonding with welding resolves the contradiction by providing both secure connection and maintained airtightness.
Solution Approach 2:
The patent utilizes the composite structure of the cable jacket material and cable connection unit material that can be welded together. By selecting materials compatible for welding (such as thermoplastic materials), the patent achieves a unified composite structure that maintains airtightness while withstanding stress, eliminating the need for separate bonding materials.
2Adaptability or versatility
If the cable bends at the secured part, then connection flexibility is achieved, but stress damages the bonding material
Solution Approach 1:
The patent replaces the bonding material-based connection with a welding-based connection. The welded joint creates a more robust connection that can withstand cable bending and flexing without deteriorating, while still allowing necessary flexibility. This resolves the contradiction by providing connection integrity that survives mechanical stress from bending.
3Ease of manufacture
If bonding material is used to secure cable, then assembly is simplified, but airtightness is reduced
Solution Approach 1:
The patent replaces the bonding material application process with a welding process. The welding can be performed automatically with precise control, creating a seamless joint that maintains airtightness. While welding requires heat control, it eliminates the need for bonding material selection, application, and curing steps, potentially simplifying the overall manufacturing process while ensuring airtightness.
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 method effectively improves the airtightness of the intraoral sensor package, as demonstrated by successful leak tests under various pressure conditions and immersion in water, achieving IP67 standards and maintaining integrity over extended periods.
Implementation Method 1
a first step of arranging the signal cable in a first mold, then filling the first mold with a first resin, and heating the first mold, so as to mold the cable connection unit having the jacket of the signal cable welded thereto
Implementation Method 2
a fourth step of resin-sealing the joint and cable connection unit onto each other
Data Source
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AI summary
A method for manufacturing an intraoral sensor having improved airtightness within its package is provided. A method for manufacturing this intraoral sensor comprises a first step S1 of arranging the signal cable 2 in a first mold, then filling the first mold with a first resin, and heating the first mold, so as to mold the cable connection unit 14 having the jacket 2c of the signal cable 2 welded thereto; a second step S2 of preparing the joint 13; a third step S3 of arranging the cable connection unit 14 at a predetermined position in the joint 13 by using a second mold; and a fourth step S4 of resin-sealing the joint 13 and cable connection unit 14 onto each other.