Vehicle Sensor Assembly with Lever Assist and Ultrasonic Bonding
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Solution Overview
Problem
Current sensor mounting methods on vehicle bumper covers and fascias often result in a shorter crush distance due to the use of mechanical fasteners like studs and nuts, which can lead to sensor damage and reduced operational time during impacts, and also face aesthetic design constraints that limit the use of conventional fasteners.
Innovation Solution
A sensor assembly is integrated with a bumper beam and bumper cover, featuring a housing with a planar tab bonded to the inner surface, eliminating the need for mechanical fasteners by using ultrasonic welding or adhesive bonding, and incorporating a lever mechanism that rotates to secure the sensor in place, maximizing the crush distance and minimizing the number of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fasteners like studs and nuts are used to mount sensors on bumper covers, then the sensor can be securely attached, but the crush distance is reduced leading to sensor damage and reduced operational time during impacts
Solution Approach 1:
The patent replaces mechanical fasteners (studs and nuts) with ultrasonic welding or adhesive bonding to attach the sensor assembly to the bumper cover. This substitution eliminates the need for protruding fasteners that reduce crush distance, allowing the sensor to be positioned closer to the impact surface while maintaining secure attachment and improving durability during impacts.
2Reliability
If mechanical fasteners like studs and nuts are used to mount sensors, then secure attachment is achieved, but aesthetic design constraints are violated due to visible fasteners
Solution Approach 1:
The patent substitutes mechanical fasteners with ultrasonic welding or adhesive bonding methods that create a flush, invisible attachment. The sensor assembly is bonded directly to the bumper cover surface, eliminating visible studs and nuts, thereby maintaining both secure attachment and aesthetic appearance consistent with the vehicle's design.
3Ease of manufacture
If conventional fastener methods are used, then sensor mounting is achieved, but assembly complexity increases due to multiple components and steps
Solution Approach 1:
The patent merges multiple components into a single integrated sensor assembly that attaches as one unit to the bumper cover. The sensor, housing, and mounting features are combined into a single assembly that can be attached via ultrasonic welding or adhesive bonding in one operation, eliminating the need for separate studs, nuts, and multiple assembly steps, thereby reducing overall complexity.
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 configuration enhances sensor durability by increasing the crush distance, allowing for more time to operate during impacts and simplifies the assembly process while adhering to aesthetic design requirements, thereby improving vehicle safety and reducing assembly complexity.
Implementation Method 1
A sensor assembly is integrated with a bumper beam and bumper cover, featuring a housing with a planar tab bonded to the inner surface, eliminating the need for mechanical fasteners by using ultrasonic welding or adhesive bonding
Data Source
AI summary
A fascia assembly may include a fascia having an inner surface, a sensor assembly including a housing integrated with the inner surface, a sensor having a connector, and a lever rotatably attached to the sensor. The lever may be configured to selectively rotate between first and second positions when inserted into the housing, and may include a tab to prevent mating access to the connector when the lever is in the first position but not in the second position.