Vehicle Sensor Lead Wire Sealing via Curved Cover and Rubber Bush
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Solution Overview
Problem
Existing vehicle sensors face challenges in maintaining water resistance and structural integrity when increasing the number of lead wires, as the caulking section's structural strength is low, leading to potential water intrusion due to uneven compression and deformation.
Innovation Solution
A vehicle sensor design featuring a metallic cylindrical cover with a rubber bush and a curved portion that radially contracts to support lead wires, enhancing water resistance by preventing deformation and maintaining high sealing pressure, even with increased lead wire counts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of lead wires is increased, then the electrical connection capability is improved, but the sealing pressure becomes uneven and water resistance deteriorates
Solution Approach 1:
The patent divides the sealing function into two independent components: the rubber bush provides primary sealing around each lead wire individually, while the curved portion provides secondary sealing at the base end. This segmentation allows each component to specialize in its sealing function, maintaining water resistance even as the number of lead wires increases.
Solution Approach 2:
The patent applies different sealing mechanisms at different locations: the rubber bush provides localized sealing at each lead wire insertion point, while the curved portion provides distributed sealing along the base end. This local quality approach ensures uniform sealing pressure distribution regardless of the number of lead wires.
2Ease of manufacture
If the caulking section is positioned at the end of the protection cover, then the assembly is simplified, but the structural strength at the end section becomes low causing deformation
Solution Approach 1:
The patent introduces a curved portion at the base end of the protection cover, replacing the conventional flat end structure. This curvature provides geometric strength to resist radial contraction forces during caulking, preventing deformation while maintaining assembly simplicity. The curved shape distributes stress more effectively than a straight end section.
3Force
If the protection cover is radially contracted to secure lead wires, then the lead wire fixation is improved, but the compression state becomes uneven allowing water droplet intrusion
Solution Approach 1:
The patent introduces the rubber bush as an intermediary component between the lead wires and the protection cover. The rubber bush deforms elastically under radial contraction to provide uniform compression around each lead wire, while the curved portion acts as a mediator to distribute the contraction force evenly, preventing localized over-compression that would create sealing gaps.
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 design effectively prevents water intrusion and maintains structural integrity by increasing the strength of the base end of the cylindrical cover and the compression capacity of the bush, ensuring stable sealing and ventilation, even with varying lead wire pitches.
Implementation Method 1
a rubber bush (4) arranged in a partial inner space (3in) of the cylindrical cover (3) in being positioned on an inner side of a base end (3bnd) of the cylindrical cover (3)... the bush (4) to deform
Implementation Method 2
The cylindrical cover (3) is provided with a curved portion (31) having a base end (3bnd) of which the whole circumferential edge is bent radially inward
Implementation Method 3
the lead wires inserted through the insertion holes are supported by radial contraction of the cylindrical cover (3) at a portion near to a base end (3bnd) of the cylindrical cover (3)
Data Source
AI summary
A sensor for a vehicle 1 is provided with a sensor element, plurality of lead wires electrically connected to the sensor element, a metallic cylindrical cover and a rubber bush positioned in a partial inner-space of a base end of the cylindrical cover. Radial contraction of the cylindrical cover and compression of bush, deforming the bush radially inward thereof, supports the leads wires inserted through each of the respective through-holes. The cylindrical cover is provided with a curved portion having a base end of which a whole circumferential edge is bent radially inward, thereby producing the curved portion opposing a rim of the bush in an axial direction.