RF Sensor Module Mounting Ears Bracket Design
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Solution Overview
Problem
Existing radio frequency sensor modules for vehicle exhaust control systems lack a secure and reliable mounting mechanism that ensures proper sealing and electrical connectivity, leading to potential contamination and performance issues.
Innovation Solution
A radio frequency sensor module design featuring a bracket with mounting ears, a printed circuit board, and a cover that are clipped together with flexible fingers, along with a mounting bolt system through C-shaped inserts, providing a secure and sealed mounting to the vehicle exhaust system housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mounting mechanism is added to secure the radio frequency sensor module, then reliability and sealing are improved, but device complexity increases
Solution Approach 1:
The mounting ears are integrated into the bracket structure, with C-shaped mounting inserts nested within the through-apertures of the mounting ears. The bracket itself is nested within the housing, creating a hierarchical nested structure that provides secure mounting without adding external complexity
Solution Approach 2:
The mounting function is merged with the bracket structure by incorporating mounting ears directly into the bracket. The sealing function is merged with the mounting function through the integrated design where the bracket with mounting ears simultaneously provides both structural support and sealing against the housing
2Ease of operation
If mounting ears with through-apertures are added to the bracket, then ease of mounting is improved, but device complexity increases
Solution Approach 1:
The mounting ears with co-linear through-apertures are pre-formed as integral parts of the bracket structure during bracket manufacturing. The C-shaped mounting inserts are pre-positioned within the through-apertures, so that during installation, the module can be directly mounted to the housing without additional assembly steps for creating mounting features
Solution Approach 2:
The mounting ears serve multiple functions: they provide structural support for the bracket, create sealed interfaces with the housing through their configuration, and facilitate easy mounting through co-linear through-apertures that align with housing features. This multi-functionality reduces the need for separate mounting components
Data Source
AI summary
A radio frequency sensor module adapted for mounting a vehicle exhaust system structure. A bracket on the module includes a first mounting ear defining a first through aperture. A printed circuit board is coupled to the bracket. A cover defines an opening and an interior cavity in communication with the opening. The bracket and the cover are coupled together in a relationship with the printed circuit board extending through the opening in the cover and into the interior cavity of the cover and the first and second mounting ears in an abutting and overlying relationship. A mounting bolt extends through the respective first and second through apertures in the respective first and second mounting ears for securing the radio frequency module to the housing of a vehicle exhaust system.