Optical Proximity Sensor Housing with U-Bend Tabs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Optical proximity sensors are prone to unwanted tilting due to minor gaps between the housing and substrate, leading to potential damage and improper sizing, which can result in the sensor being labeled as defective.
Innovation Solution
The housing is constructed using a single piece of material with strategically placed tabs that form a u-bend feature and support extensions, allowing for variances in machining tolerances and minimizing tilting by distributing forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the outer sidewalls of the modules are not machined to fit snugly around the substrate, then the housing is prone to unwanted tilting, but machining to fit snugly increases manufacturing complexity and cost
Solution Approach 1:
The patent changes the geometric parameters of the housing by adding tabs with specific dimensions (e.g., tab length, width, and fold geometry) that can be manufactured with standard tolerances. These tabs, when folded into u-bend configurations, provide mechanical support that compensates for variations in substrate dimensions, allowing the housing to remain stable without requiring ultra-precise machining of the outer sidewalls.
Solution Approach 2:
The housing is segmented into functional portions: outer sidewalls for enclosure, and separate tabs for mechanical support and positioning. This segmentation allows each portion to be optimized independently - the outer sidewalls can be manufactured with relaxed tolerances while the tabs provide the necessary precision and stability through their folding mechanism.
2Ease of manufacture
If gaps are present between the outer sidewalls and substrate edge, then manufacturing is easier, but the u-bend feature acts as a pivot point causing tilting
Solution Approach 1:
The tabs serve as intermediary elements between the housing and substrate. Instead of relying on a direct snug fit between the outer sidewalls and substrate (which requires high precision), the tabs act as mediators that bridge the gap, providing mechanical support and preventing the housing from tilting while allowing easier manufacturing with larger tolerances.
Solution Approach 2:
The solution moves from a two-dimensional fit (outer sidewall against substrate surface) to a three-dimensional solution by adding tabs that fold into u-bend configurations. These tabs extend in the vertical dimension and can be positioned at multiple locations around the substrate perimeter, distributing support forces and preventing tilting without requiring tight clearances in the horizontal plane.
3Manufacturing precision
If the housing is at the high end of manufacturing tolerance and substrate at the low end, then a gap is created, but this gap allows more tilt to occur
Solution Approach 1:
The tabs provide beforehand cushioning by pre-establishing mechanical support and alignment features that compensate for potential gaps. The u-bend configuration of the tabs creates a resilient connection that can accommodate dimensional variations between housing and substrate, cushioning against the effects of tolerance stack-up before tilting can occur.
Solution Approach 2:
The tabs are designed to preemptively counteract the tilting force that would result from gaps. By providing multiple support points and creating a rigid folded structure, the tabs generate preliminary anti-action forces that prevent the housing from pivoting on the u-bend feature, even when gaps exist due to tolerance variations.
Data Source
AI summary
An optical proximity sensor and housing for the same are disclosed. The housing is provided with at least two support structures and at least two modules. A first of the support structures transfers vertical forces applied to one end of a module to an opposite end of the opposite module. A second of the support structures inhibits a pivoting of the modules about the first support structure.