Sensor Device Terminal Connection via Segmentation
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Solution Overview
Problem
The manufacturing cost and time of sensor devices for exhaust gas recirculation systems are increased due to the need for multiple molds for various connector shapes, and the insert mold process elongates electrical part terminals, compromising cost efficiency and precision.
Innovation Solution
A sensor device configuration where the sensor unit, connector unit, and cover unit are jointly formed without a single mold, with terminals exposed on the surface for connection, allowing for flexible arrangement and reduced manufacturing costs through a terminal connection member formed by bending, eliminating the need for internal wiring and selective plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If insert mold is performed to the cover member and electrical part terminal, then the connector housing can be manufactured according to shape requirements, but the manufacturing cost is increased
Solution Approach 1:
The device is divided into three separate units: sensor unit, connector unit, and cover unit. Each unit is manufactured independently using simple casting molds, avoiding the need for complex insert molding processes. The units are then assembled together with terminals connected at exposed positions on the cover unit surface.
Solution Approach 2:
Terminals are positioned and connected at exposed positions on the cover unit surface before final assembly. This preliminary connection eliminates the need for complex internal wiring and reduces manufacturing steps, thereby lowering costs while maintaining shape adaptability.
2Adaptability or versatility
If insert mold is performed to the cover member, then the connector housing can accommodate various shapes, but the length leading the electrical part terminal is elongated
Solution Approach 1:
By separating the device into modular units with terminals exposed on the cover unit surface, the terminal length is minimized. Each unit can be independently sized, allowing optimal terminal length without requiring elongated housing structures.
Solution Approach 2:
Terminals are arranged on the surface of the cover unit rather than being routed through the interior volume. This surface-level arrangement reduces the effective length and complexity of terminal routing while maintaining shape adaptability.
3Manufacturing precision
If units are jointly formed with one pattern mold, then manufacturing precision can be maintained, but the manufacturing cost increases due to mold complexity
Solution Approach 1:
The device is segmented into separate units manufactured with simple casting molds. Terminal connection precision is achieved through exposed position alignment on the cover unit surface rather than through complex integrated molding, reducing mold costs while maintaining precision.
Solution Approach 2:
The cover unit serves as an intermediary platform with exposed terminal positions that facilitate precise connections between sensor and connector units. This intermediary structure enables accurate terminal alignment without requiring complex multi-cavity or insert molds.
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 reduces manufacturing costs, maintains high precision by eliminating the need for complex molds and internal wiring, and allows for flexible terminal arrangements while minimizing plating costs by only plating exposed terminals.
Implementation Method 1
a terminal connection member for connecting any two terminals or all of the terminals disposed in the sensor unit, the connector unit, and the cover unit
Data Source
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AI summary
The invention provides a sensor device which maintains high precision of terminals which connect electrically units forming a main body of a device and reduces cost for manufacturing the main body of the device. The device includes a sensor unit 10, a connector unit 30 which receives a connector for a controller and connects electrically the controller to the sensor unit 10, and a cover unit 20 which receives the sensor unit 10 and the connector unit 30, in which the units are jointed to each other, wherein any two or all of the terminals disposed in the sensor unit 10, the connector unit 30, and the cover unit 20 are connected at positions where the terminals are exposed from the surface of the cover unit 20.