Non-Regular Polygon Sensor Housing for Compact Injector Integration
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Solution Overview
Problem
Conventional sensor devices integrated into internal-combustion engine injectors are inefficient in using space due to the circular shape of the mold IC not matching the regular polygon engaging part, leading to a larger injector structure and reduced marketability.
Innovation Solution
The sensor device features a housing with a non-regular polygon engaging part that allows for precise positioning during screw-fixing, enabling effective use of space by shifting the electric circuit unit to the margin area, and the engaging part has axial or non-axial symmetry, with the mold IC's resin layer chamfered to fit within the available space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular mold IC is disposed in a regular polygon engaging part, then the sensor device can be manufactured with standard components, but the space utilization becomes inefficient and the overall structure becomes larger
Solution Approach 1:
The patent applies asymmetry by changing the engaging part shape from a regular polygon to a non-regular polygon that matches the rectangular footprint of the mold IC. This asymmetric design allows the mold IC to be positioned optimally within the housing, eliminating wasted space that occurs with circular components in regular polygon configurations. The non-regular polygon shape is specifically designed to accommodate the rectangular mold IC while maintaining manufacturability through standard molding processes.
2Device complexity
If the mold IC is positioned in the projected plane of the engaging part, then the structure is simplified, but space around the sensor device is wasted when the mold IC shape does not match the engaging part shape
Solution Approach 1:
The patent applies local quality by designing the engaging part with a non-regular polygon shape that specifically matches the local footprint of the mold IC. This allows different regions of the housing to serve different functions: the engaging part area is optimized for mechanical engagement while the mold IC area is optimized for electronic component placement. The non-regular polygon shape creates local space optimization around the mold IC without complicating the overall structure.
3Ease of operation
If the housing is screwed into the member without strict position management, then the assembly process is simpler, but the position in rotating direction becomes unsettled
Solution Approach 1:
The patent applies asymmetry through the non-regular polygon engaging part design, which creates a unique orientation for the housing during assembly. The asymmetric shape provides mechanical guidance that automatically orients the housing correctly as it is screwed into the member, eliminating the need for complex positioning mechanisms while ensuring precise and consistent positioning. The jig that engages with the non-regular polygon engaging part also benefits from this asymmetric design, as it can only engage in one correct orientation.
Data Source
AI summary
A sensor device where a jig is engaged to an engaging part formed in the housing, and the housing is rotated by the jig and screwed into the member to be mounted. A position in the rotating direction of the housing is configured to have a substantially constant position at the time the screw-fixing of the housing and the member to be mounted is completed. A shape of the engaging part when seen along a direction of a rotational axis X of the housing is formed into a non-regular polygon, and the engaging part and a mold IC are shifted and disposed to a side that has a margin in a space in the housing or around the mold IC so that the space around the sensor device is used effectively.