Sensor Cable Sealing via Inclined Injection Molding
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Solution Overview
Problem
The existing sealing structure of physical quantity measurement sensors, which uses a separately formed sealing member, increases the number of components and manufacturing costs, and may not effectively prevent water intrusion due to gaps between the sealing member and the cable.
Innovation Solution
A method of manufacturing a physical quantity measurement sensor where the resin molded body covers the cable's end portion, with the sheath being partially melted and adhered to the resin molded body using an injection hole inclined relative to the cable's axis, eliminating the need for a separate sealing member and enhancing sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separately formed sealing member is used to seal between the sensor and cable, then sealing properties are improved, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The sealing member is merged with the resin molded body into a single integrated component. The resin molded body simultaneously provides structural support and sealing function, eliminating the need for separate sealing members while maintaining effective sealing between the sensor and cable assembly.
2Reliability
If a separately formed sealing member is used, then sealing function is provided, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The sealing function is merged into the resin molded body manufacturing process. The resin is molded to directly cover and seal the cable connection area, combining the sealing function with the existing structural housing in a single manufacturing step, thereby simplifying the overall manufacturing process.
3Ease of manufacture
If only the inner surface of the sealing member is attached to the cable sheath, then attachment is achieved, but water intrusion prevention is insufficient
Solution Approach 1:
The sealing approach transitions from single-sided attachment (inner surface only) to multi-dimensional sealing. The resin molded body provides sealing from multiple directions and surfaces, creating a comprehensive seal that prevents water intrusion from various pathways around the cable connection.
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 approach simplifies the manufacturing process, reduces costs, and ensures effective sealing between the sensor and cable, preventing water intrusion while maintaining the sensor's quality.
Implementation Method 1
the sheath arranged in the mold is at least partially melted by heat of the molten resin injected through the injection hole
Data Source
AI summary
A method of manufacturing a physical quantity measurement sensor, which includes a measurement portion, a cable including a conductor electrically connected to the measurement portion and a sheath, and a resin molded body covering at least an end portion of the cable. The method includes arranging the measurement portion connected to the cable in a mold, and molding the resin molded body by injecting a molten resin toward the sheath through an injection hole formed in the mold. The injection hole is formed at a position distant from the cable and includes a central axis inclined with respect to the axial direction of the cable at an opening facing an inside of the mold. The molding is conducted such that the sheath arranged in the mold is at least partially melted by heat of the molten resin injected through the injection hole and is adhered to the resin molded body.