Meander Conductor Track Positioning in Rotor Injection Molding

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Solution Overview

Problem

The precise alignment and positioning of a meandering conductor track structure with respect to a rotor sleeve in rotation angle sensor units pose challenges during manufacturing, particularly in injection molding, leading to inaccuracies and potential damage.

Innovation Solution

Incorporating inwardly projecting positioning protrusions on the conductor track structure for form-fit or force-fit positioning within an injection mold, allowing for precise alignment and affixing during the molding process, which can be designed as nose-shaped or more complex geometries, ensuring stability and material efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If meandering conductor track structures are affixed to the rotor sleeve by injection molding, then the conductor track structure can be integrated with the rotor sleeve, but the precise positioning of the conductor track structure with respect to the rotor sleeve during injection molding is difficult to achieve

Engineering Contradiction:

Improveintegration of conductor track structure with rotor sleeveVSAvoidpositioning accuracy of conductor track structure

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Positioning protrusions are pre-formed on the conductor track structure before injection molding, enabling preliminary positioning that ensures accurate alignment with the rotor sleeve during the molding process. This preliminary action prevents positioning errors that would otherwise occur during injection molding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Positioning protrusions act as intermediary elements between the conductor track structure and the rotor sleeve, providing a mechanical interface that ensures precise positioning. These protrusions mediate the positioning relationship, allowing accurate alignment without requiring complex molding techniques.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If additional retainers are used to achieve precise relative positioning between the conductor track structure and the rotor sleeve, then positioning accuracy improves, but the device complexity increases

Engineering Contradiction:

Improverelative positioning accuracyVSAvoidnumber of additional components

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The positioning function is merged into the conductor track structure itself through integrated positioning protrusions, eliminating the need for separate retainer components. This combining of positioning functionality into the existing structure achieves precise positioning while maintaining device simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductor track structure provides its own positioning capability through built-in positioning protrusions, making the system self-sufficient. The structure serves dual purposes: conducting electricity and providing precise positioning, thereby eliminating the need for additional positioning components.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If the conductor track structure is designed as an integral component with the rotor sleeve, then manufacturing simplicity improves, but the alignment precision between the conductor track structure and rotor sleeve becomes difficult to achieve

Engineering Contradiction:

Improvemonolithic component designVSAvoidalignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Positioning protrusions are pre-formed on the conductor track structure before the injection molding process, establishing predetermined alignment references. This preliminary action ensures that even in an integral design, the conductor track structure aligns precisely with the rotor sleeve during manufacturing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The positioning protrusions create localized features with specific geometric properties that ensure precise alignment at critical points. By concentrating positioning functionality in specific local areas rather than distributing it uniformly, the design achieves high alignment precision while maintaining the simplicity of an integral component structure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20240410721A1Conductor track structure, rotor, rotation angle sensor unit and method for producing a rotor for a rotation angle sensor unit

Publication Date: 2024.12.12 HELLA GMBH & CO KGAA

AI summary

A conductor track structure for a rotor of a rotation angle sensor comprising an annularly designed conductor track with a meander-shaped conductor track profile. At least one positioning projection projecting inwards in a radial direction for the positive and/or non-positive positioning of the conductor track structure is arranged on the conductor track in an injection molding tool. A rotor having a conductor track structure, a rotation angle sensor unit having a rotor, and a method for producing a rotor are also provided.