Multi-Directional Force Sensor With One-Piece Metal Support Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multi-way force sensors are either too stiff or require significant space, making them unsuitable for applications where a compact, cost-effective, and simple metal-based solution is needed.
Innovation Solution
A metal sensor element is created by cutting a single rectangular or square metal plate into strip-shaped support elements and a cloverleaf-shaped sensor plate with four sensor wings, allowing for a rigid, compact, and inexpensive design that can detect forces in multiple directions using a capacitive measuring system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a housing is used to enclose the sensor element, then the sensor is protected and structurally stable, but the device size increases and manufacturing complexity increases due to demolding difficulties
Solution Approach 1:
The patent removes the housing component entirely from the sensor design. The sensor element consisting of the sensor plate and support elements is exposed without encasement, eliminating the space occupied by housing walls while maintaining structural functionality through the inherent rigidity of the metal sensor components.
Solution Approach 2:
The sensor plate and support elements are integrally connected as a single piece formed from one metal plate, combining multiple functional components into one unified structure. This eliminates the need for separate housing to hold these components together, reducing overall device volume while maintaining structural stability.
2Reliability
If a housing is used to enclose the sensor element, then the sensor is protected and structurally stable, but manufacturing complexity and cost increase due to demolding challenges
Solution Approach 1:
By removing the housing entirely, the patent eliminates the complex demolding process associated with molded plastic housings. The metal sensor element can be manufactured using simpler processes such as laser cutting, punching, or bending of metal plates, which do not require mold release and are more cost-effective.
Solution Approach 2:
The sensor plate and support elements are formed as one integral piece from a single metal plate, eliminating the need for separate housing components and assembly steps. This unified structure simplifies manufacturing to primarily cutting and shaping operations on metal, which are more straightforward than molding and assembling plastic components.
3Strength
If the sensor element is made entirely from metal, then rigidity and durability are improved, but manufacturing complexity increases due to demolding difficulties
Solution Approach 1:
The entire sensor element including the sensor plate and support elements is formed from one piece of metal plate, creating a rigid, durable structure. The integral construction eliminates weak points from joints between different materials or components, maximizing rigidity while simplifying manufacturing to single-material processing.
Solution Approach 2:
The patent employs cost-effective metal forming processes such as laser cutting, punching, or simple bending operations on metal plates. These processes are more economical than creating molds for plastic injection molding, especially for low-volume production, and allow for rapid prototyping and manufacturing without expensive tooling investments.
4Volume of moving object
If the sensor element is made compact without housing, then device size is reduced, but structural stability may be compromised
Solution Approach 1:
The sensor plate and support elements are integrally connected as a single rigid structure formed from one metal plate. This unified construction provides inherent structural stability without requiring external housing, as the metal itself provides the necessary rigidity and strength to maintain structural integrity in the compact form factor.
Solution Approach 2:
The patent uses metal material properties to achieve structural stability in a compact design. The inherent strength-to-weight ratio and rigidity of metal allow the sensor element to maintain structural stability without the added volume of protective housing, leveraging material properties to compensate for the reduced structural envelope.
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 enables a compact, cost-effective, and rigid multi-way force sensor capable of detecting forces in multiple directions with a simple structure, suitable for applications like motor vehicle seat adjustment switches, without the need for complex housing or demolding challenges.
Implementation Method 1
a capacitive multi-way force sensor is known from German patent application DE 10 2014 014 021 A1... the capacitance values of the capacitors formed by the arrangement of plate and surfaces change with the pivoting movement of the sensor pin
Data Source
AI summary
What is described is an electrical multi-directional force sensor having a sensor pin able to be moved from its neutral position in at least two actuation directions, which sensor pin moves back into its neutral position again when an actuation force ceases to be applied, having a sensor plate that is connected to the sensor pin and that is able to be pivoted counter to a circuit board by a movement of the sensor pin, which circuit board has an electrical measurement system, the output signal from which depends on the position of the sensor plate, wherein the sensor plate is integrally connected to a plurality of strip-shaped support elements that each have an end section in the form of a boss, and wherein the sensor plate and the support elements are cut free in one piece from a metal plate.