Resin-Isolated Sensor Assembly for Low-Interference Mounting
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Solution Overview
Problem
Existing sensor attachment brackets interfere with radio waves emitted by sensors due to metal components, and covers can become large, preventing accurate detection and allowing foreign matter to adhere to the sensors.
Innovation Solution
A sensor assembly comprising a metal-made sensor pedestal bracket, a resin plate attached to the pedestal bracket, and a resin cover that accommodates the sensor, reducing interference with metal and protecting the sensor from foreign matter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal-made sensor pedestal bracket is used to attach the sensor, then the sensor can be securely mounted, but the metal bracket interferes with the radio wave emitted by the sensor
Solution Approach 1:
A resin plate is introduced as an intermediary component between the metal sensor pedestal bracket and the sensor. This resin plate acts as a mediator that allows the sensor to be securely mounted on the metal bracket while preventing the metal from interfering with the radio wave emission, thus resolving the contradiction between mounting stability and radio wave interference
Solution Approach 2:
The solution uses a composite structure combining metal (pedestal bracket) and resin (plate and cover). The metal provides structural strength and mounting stability, while the resin provides electromagnetic transparency to allow radio wave passage, creating a composite system that satisfies both requirements
2Reliability
If a cover is added to protect the sensor from foreign matter and contact, then the sensor is protected, but the cover becomes large
Solution Approach 1:
The resin plate is designed to be fitted inside the resin cover, creating a nested structure where the plate is accommodated within the cover's internal space. This nesting approach allows the sensor assembly to be protected while minimizing the overall volume occupied by the cover
3Reliability
If the resin plate is fitted to the cover, then the sensor is protected from foreign matter, but the assembly complexity increases
Solution Approach 1:
The resin plate and resin cover are made of the same material and designed to fit together seamlessly, merging the protection function into a unified resin assembly. This combining approach simplifies the overall structure compared to mixing metal and resin components, reducing assembly complexity while maintaining protection effectiveness
Data Source
AI summary
An object of the present disclosure is to provide a sensor assembly in which a radio wave emitted by a sensor is not interfered by a metal-made member, and that is capable of preventing foreign matter from adhering to the sensor and/or preventing contact between the sensor and another member. To this end, the sensor assembly includes a metal-made sensor pedestal bracket, a resin plate attached to the sensor pedestal bracket, a sensor attached to the resin plate, and a cover to which the resin plate is fitted and that accommodates the sensor within a space formed by the cover and the resin plate.