Vehicle Sensor Cover Attachment With Elastic Gap Compensation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional attachment structures for vehicle exterior detection sensors often result in design gaps due to gravitational forces acting on the sensor cover, causing misalignment and aesthetic issues between the sensor cover and the overhead console.

Innovation Solution

A cover member attachment structure that includes a support member fixed to the vehicle roof, a console member, and a cover member supported by a glass member with an elastic member interposed between the cover member and the support member, allowing the cover member to be biased by the elastic restoring force to reduce misalignment and design gaps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the cover member is fixed rigidly to the support member, then the assembly is stable and simple, but gravitational force causes the cover member to sag and create design gaps

Engineering Contradiction:

Improveassembly stabilityVSAvoidalignment precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent changes the mechanical parameter of the connection from rigid to elastic by introducing an elastic member (clip member with elastic deformation portion) between the cover member and support member. This allows the connection to maintain stability while accommodating gravitational sagging through elastic deformation, preventing design gaps.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces dynamic characteristics to the otherwise static assembly by using an elastic member that can deform under load. The elastic member dynamically adjusts to gravitational forces, allowing the cover member to maintain proper alignment while bearing its own weight and the weight of housed objects.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If the cover member is allowed to move freely, then alignment gaps are reduced, but the assembly becomes unstable and complex

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces an intermediary elastic member (clip member) between the cover member and support member. This intermediary component mediates between the conflicting requirements of stability and alignment precision, providing both support and flexibility to eliminate design gaps while maintaining assembly stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If multiple fastening components are used to prevent sagging, then alignment precision is maintained, but device complexity and production cost increase

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single integrated clip member: attachment function (securing cover member to support member), elastic compensation function (absorbing gravitational sagging), and alignment function (maintaining proper positioning). This consolidation reduces assembly complexity and production costs while achieving the desired alignment precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The clip member is designed as a multi-functional component that simultaneously provides mechanical attachment, elastic deformation for gap elimination, and positioning alignment. This universal component replaces what would traditionally require multiple separate fasteners, alignment features, and adjustment mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 structure effectively reduces design gaps between the cover member and console member by utilizing the elastic member's biasing force, enhancing the aesthetic appeal and assembly precision while reducing component count and production costs.

Implementation Method 1

the second end portion of the cover member is biased to the first end portion side with respect to the support member, by the elastic restoring force of the elastic member

Methodology Applied

Scientific EffectElastic restoring force: Elasticity

Data Source

PatentEP4631793A1Cover member attachment structure

Publication Date: 2025.10.15 TOYOTA JIDOSHA KK

Figure 1
Figure 2
Figure 3

AI summary

A cover member attachment structure (10) includes; a support member (20) that is fixed to a roof member (18) of a vehicle (12); a console member (40); and a cover member (30) that is disposed so as to be adjacent to the console member (40) in a vehicle front-rear direction, such that a first end portion (30A) of the cover member (30) in the vehicle front-rear direction is supported by a glass member (14) and a second end portion (30B) of the cover member (30) in the vehicle front-rear direction is attached to the support member (20), the cover member (30) housing a housed object between the cover member (30) and the glass member (14). In the attachment structure (10), an elastic member (16) is interposed between the second end portion (30B) of the cover member (30) and the support member (20).