Resin Retainer Snap-Fit for Vehicle Distance Sensor Mounting
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Solution Overview
Problem
Conventional ultrasonic sensors for vehicles require complex installation processes and metal springs, leading to increased production costs and potential plastic deformation, making them difficult to use with bumpers of varying thicknesses.
Innovation Solution
A distance sensor design featuring a resin-made retainer with annular base, arms, and protrusions that establish a snap-fit mechanism to secure the sensor to the bumper, eliminating the need for metal springs and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal springs are used to secure the ultrasonic sensor to the bumper, then the sensor can be firmly fixed, but the production cost increases and the installation process becomes more complex
Solution Approach 1:
The patent removes the metal springs from the assembly, extracting the problematic component that caused complexity and cost issues. The retainer directly engages with the bumper without requiring separate spring elements, simplifying both the device structure and installation process while maintaining securing function.
Solution Approach 2:
The retainer is designed to automatically secure itself to the bumper through its own elastic deformation. The resilient arms with protrusions self-adjust and self-lock into the bumper holes without requiring additional fastening mechanisms or complex assembly steps, making the system self-sufficient.
2Strength
If metal springs are used to secure the ultrasonic sensor, then the sensor can be firmly fixed, but production cost increases
Solution Approach 1:
The patent replaces expensive metal springs with a cheaper resin retainer that can be molded as a single piece. The retainer is designed to be cost-effective while maintaining sufficient securing strength, eliminating the need for costly metal components and reducing overall manufacturing expenses.
Solution Approach 2:
The retainer is made of resin material that combines flexibility and strength properties. This composite approach allows the retainer to be both cost-effective and mechanically sufficient, replacing metal components with a material that offers adequate performance at lower cost.
3Ease of operation
If the assembly of bezel and casing is inserted into the mount hole, then the sensor can be installed, but plastic deformation of metal springs occurs leading to failure in nipping the bumper wall
Solution Approach 1:
By removing the metal springs entirely, the patent eliminates the risk of plastic deformation that occurs during installation. The resilient arms are designed to elastically deform within safe limits and maintain their securing capability without permanent deformation or failure to nip the bumper wall.
Solution Approach 2:
The patent changes the material parameter from metal to resin, which alters the deformation characteristics. The resin retainer exhibits elastic deformation behavior that is more forgiving during installation, preventing permanent deformation and ensuring reliable securing without the dimensional changes that cause metal spring failure.
4Strength
If the conventional ultrasonic sensor structure is used, then the sensor can be secured to the bumper, but it is difficult to use with bumpers having different thicknesses
Solution Approach 1:
The retainer is designed with resilient arms that can dynamically adjust their deformation degree based on the bumper thickness. The elastic properties allow the protrusions to compress and expand, adapting to various bumper thicknesses while maintaining secure engagement, making the sensor compatible with different bumper specifications.
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 design facilitates easy and secure installation of ultrasonic sensors on vehicle bumpers, reducing production costs and preventing plastic deformation, while accommodating different bumper thicknesses.
Implementation Method 1
The protrusions are elastically deformed inwardly of the base when the protrusions are forced into the mount hole of the bumper to retain the distance sensor in the bumper and return to original positions thereof when the protrusions have passed the mount hole
Data Source
AI summary
A distance sensor equipped with a mount for mounting the sensor in a mount hole of a bumper of a vehicle. The mount includes a casing with a sensor holder, a bezel, and a resin-made retainer. The bezel is made up of a cylindrical member joined to the sensor holder and a flange having an outer diameter greater than an inner diameter of the mount hole. The retainer includes an annular base joined to the bezel, a plurality of arms, and a plurality of protrusions. The protrusions extend from ends of the arms radially outward of the base and serve to establish a snap-fit on a peripheral edge of the mount hole, thereby nipping a wall of the bumper between the protrusions and the flange tightly to secure the distance sensor to the bumper.