Metal Wire Spring for Vehicle Sensor Bracket
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Solution Overview
Problem
Existing camera brackets for vehicles, particularly those using metal or plastic plate springs, face challenges such as high production costs, complex tooling requirements, and reduced elasticity at high temperatures, leading to inefficiencies in assembly and durability.
Innovation Solution
A bracket unit comprising a plastic bracket and a metal wire spring with an elongated body and rotatably attached spring hinge parts, allowing for a snug fit and easy assembly, which maintains elasticity even at high temperatures, using a simple design with few components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal or plastic plate springs are used for attaching the camera onto the bracket, then the camera can be securely fastened, but the production costs increase and tooling requirements become complex
Solution Approach 1:
The patent changes the material parameters from plate springs to wire springs, altering the geometric configuration from flat plates to three-dimensional wire structures. This parameter change enables the spring to achieve the same fastening function while being manufactured through simpler wire bending processes rather than complex plate forming operations
Solution Approach 2:
The wire spring is divided into distinct functional segments including hinge parts for rotation, bar parts for structural support, and latch parts for securing. This segmentation allows each part to be optimized independently and simplifies the manufacturing process by enabling modular assembly from pre-formed wire components
2Reliability
If plastic or metal plate springs are used, then the camera can be attached to the bracket, but the elasticity is reduced at high temperatures
Solution Approach 1:
The patent employs a composite construction combining plastic bracket components with metal wire spring elements. The metal wire spring provides superior thermal stability and elasticity retention at high temperatures compared to plastic springs, while the plastic bracket provides structural support and integration with the camera housing
Solution Approach 2:
The invention changes the material parameters of the spring component from plastic or metal plates to metal wires, which have different thermal properties. Metal wires maintain their elastic properties at higher temperatures where plastic materials would deform and metal plates would lose flexibility
3Reliability
If plate spring systems are used, then the camera can be fastened, but the assembly and detachment processes become time-consuming
Solution Approach 1:
The wire spring incorporates rotatable hinge parts that enable dynamic movement and rotation. This dynamic capability allows the latch parts to be quickly engaged or disengaged from corresponding bracket features through simple rotational motion, significantly reducing the time required for assembly and detachment compared to static plate spring systems
Solution Approach 2:
Instead of requiring complex manual manipulation of plate springs for attachment, the invention inverts the approach by using spring-loaded latch parts that automatically engage with bracket features when the camera is inserted, enabling tool-free and rapid assembly
4Ease of manufacture
If a simple design with few components is used, then production complexity is reduced, but achieving a snug fit becomes more difficult
Solution Approach 1:
The wire spring features locally optimized geometric configurations at critical positions: hinge parts with specific rotation axes, bar parts with tailored lengths and diameters, and latch parts with precisely positioned engagement surfaces. This local quality optimization ensures accurate and snug fitting while maintaining overall design simplicity
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 solution provides a cost-effective, durable, and efficient method for attaching and detaching vehicle sensors, maintaining structural integrity and functionality over time, even in high-temperature environments, with reduced production complexity and lower component costs compared to traditional plate spring systems.
Implementation Method 1
maintains elasticity even at high temperatures
Implementation Method 2
the spring hinge part is rotatably attached to the bracket holder part, allowing the metal wire spring to rotate about the bracket holder part
Data Source
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AI summary
The application provides a bracket unit (5) for holding a vehicle sensor (1). The bracket unit (5) includes a bracket (2) and a metal wire spring (3). The bracket (2) includes a bracket plate (2j), one or more bracket holder parts (2a, 2b), one or more bracket hook parts (2h, 2i), and one or more bracket latch parts (2d, 2e, 2f, 2g). The bracket holder parts, the bracket hook parts, and the bracket latch parts are integrally connected to one side of the bracket plate (2j). The metal wire spring (3) includes an elongated body with an essentially circular cross-section. The body includes one or more spring hinge parts (3a, 3b), one or more spring bar parts (3h, 3i), and one or more spring latch parts (3d, 3e, 3f, 3g). The spring hinge part (3a, 3b) is rotatably attached to the bracket holder part (2a, 2b).