Resin Holder Mounting Sonar Sensor to Reduce Painting Costs
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Solution Overview
Problem
The existing mounting structures for sonar sensors require different paint materials for the metal detection plane and resin bumper, leading to increased painting costs and potential malfunctions due to direct contact with the bumper.
Innovation Solution
A mounting structure where the sonar sensor is attached to a holder made of the same resin material as the bumper, with a cover that covers the detection plane and is painted with the same resin material, preventing direct contact and allowing for a single painting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the detection plane is made of metal and the bumper is made of resin, then the sonar sensor can function properly, but different painting materials are required increasing painting cost
Solution Approach 1:
The patent introduces a holder as an intermediary component between the metal detection plane and the resin bumper. This holder is made of resin material that matches the bumper, allowing the metal sonar sensor to be mounted without direct contact with the bumper. The holder serves as a mediator that enables both the functional metal component and the aesthetic resin bumper to coexist while being painted with the same resin-appropriate paint material.
Solution Approach 2:
The patent segments the mounting structure into distinct components: the holder and the bumper, where the holder is specifically designed to mount the sonar sensor. This segmentation allows the holder to be made of resin (matching the bumper for painting purposes) while the sonar sensor itself can remain metal for functional reasons, thus resolving the painting material contradiction.
2Device complexity
If the detection plane is directly attached to the bumper, then the mounting structure is simple, but gaps may cause malfunctions and appearance issues
Solution Approach 1:
The holder acts as an intermediary that eliminates gaps between the detection plane and the bumper surface. By providing a dedicated mounting interface, the holder ensures proper positioning and contact while preventing direct attachment issues. This intermediary structure maintains reliability by ensuring proper sensor mounting while avoiding the gaps that would cause malfunctions.
Solution Approach 2:
The holder is pre-designed with the appropriate shape and mounting features to ensure proper alignment and contact before the sonar sensor is attached to the bumper. This preliminary preparation of the mounting interface prevents gaps and misalignment issues that would otherwise require complex adjustments or cause functional problems.
3Adaptability or versatility
If different materials are used for detection plane and bumper, then functional requirements are met, but color aging becomes inconsistent
Solution Approach 1:
The resin holder serves as a visual intermediary that matches the bumper material and color. Since the holder is made of the same resin material as the bumper, it ages and discolors at the same rate, maintaining color consistency across the bumper assembly. The metal sonar sensor remains hidden or minimal in appearance, so its different aging characteristics do not affect the overall visual consistency.
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
This solution reduces painting costs by using identical materials, maintains a smooth appearance, prevents malfunctions by filling gaps, and ensures consistent color aging, while allowing the sonar sensor to function without obstruction.
Implementation Method 1
a material of the detection plane is generally made of metal such as aluminum, but the bumper is made of resin such as PP (polypropylene). Therefore, according to each material, it is imperative to paint the detection plane by a painting material for metal and to paint the bumper by a painting material for resin.
Implementation Method 2
prevents malfunctions by filling gaps
Data Source
Figure 1~2
Figure 3
AI summary
A mounting structure for a sonar sensor includes the sonar sensor that includes a sensor main body having a detection plane and detects a distance to a detection object by sending an ultrasound from the detection plane and receiving a reflective wave reflected by the detection object, a resin member in which a hole is formed and on which the sonar sensor is mounted, and a holder that has a cover for covering the detection plane and holds the sonar sensor. The sonar sensor is installed in the holder. The holder is attached to the resin member so that the cover is inserted into the hole from an inside of the resin member and an outer surface of the cover is made almost flush-surfaced with an outer surface of the resin member. At least the cover is made of resin in the holder. According to the mounting structure, painting cost can be reduced by commonalizing painting materials.