Parking Assist Sensor Holder Live Hinge Bumper Conformity
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Solution Overview
Problem
The manufacturing of parking assist sensor (PAS) holders is costly and prone to wastage due to the need for custom tooling and strict tolerances, as each holder must match the unique shape of the bumper, and current mounting methods like ultrasonic welding are complex.
Innovation Solution
A flexible PAS holder design featuring live hinges and adhesive or self-locking mounting holes allows the holder to conform to any bumper shape without complex procedures, reducing material usage and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If custom tooling is used to manufacture PAS holders matching each bumper shape, then the holder can conform to the unique shape of the bumper, but manufacturing cost increases and material wastage occurs
Solution Approach 1:
The PAS holder incorporates a flexible body portion that can dynamically adapt to different bumper shapes through elastic deformation. The live hinge mechanism enables the holder to bend and conform to various contours without requiring custom tooling for each bumper design, thereby reducing manufacturing costs while maintaining shape conformity.
Solution Approach 2:
The holder utilizes material flexibility and elastic properties to change its shape parameters adaptively. By designing the holder with flexible materials and live hinge joints, it can alter its geometric configuration to match different bumper shapes without requiring different manufacturing tools, thus eliminating the need for expensive custom tooling.
2Manufacturing precision
If strict tolerances are applied during PAS holder manufacturing, then the holder matches the bumper shape accurately, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of manufacturing the holder with rigid precision to match bumper contours, the design employs a flexible body that can dynamically adjust its shape after manufacturing. This dynamic adaptation eliminates the need for complex manufacturing processes and strict tolerances, as the holder naturally conforms to the bumper shape through elastic deformation.
Solution Approach 2:
The holder is designed as a flexible structure with live hinges that allow it to bend and adapt to bumper contours. This flexible shell approach replaces the need for high-precision manufacturing with a simple, cost-effective structure that achieves accurate fit through its inherent flexibility rather than manufacturing precision.
3Strength
If ultrasonic welding is used to mount the PAS holder, then secure mounting is achieved, but the mounting procedure becomes complex
Solution Approach 1:
The patent replaces the complex ultrasonic welding mechanical system with a simpler adhesive bonding system. The adhesive mounting holes provide secure attachment through chemical bonding rather than mechanical welding, significantly simplifying the mounting procedure while maintaining adequate mounting strength for PAS installation.
Solution Approach 2:
The design accepts a simpler, potentially less durable mounting method (adhesive bonding) in exchange for greatly reduced operational complexity. The adhesive mounting holes provide sufficient strength for the application while allowing for easier installation and removal compared to ultrasonic welding, aligning with the principle of using simpler methods when full durability is not critical.
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
Enables efficient and cost-effective production of PAS holders that can be easily mounted on various bumper contours, minimizing wastage and simplifying assembly, while maintaining effective sensor operation.
Implementation Method 1
The PAS holder includes a body portion with one or more live hinges to provide flexibility to the body portion
Implementation Method 2
A mating surface opposite the bracket and railing can be provided with an adhesive to couple the PAS holder to the mounting component
Data Source
Figure 1
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Figure 3A
AI summary
Examples relating to a parking assist sensor holder (204) are described herein. In one example, the holder includes a body portion (208) having a bracket (212) to couple a parking assist sensor (202) thereto and an aperture for accommodating a sensing portion (99) of the parking assist sensor (202). The holder further includes at least one live hinge (314) for providing flexibility to the body portion (208) to match a curvature of a mounting component for mounting the parking assist sensor (204).