Sensor Housing Slide Locking Mechanism for Sheet Metal
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Solution Overview
Problem
Current methods for attaching automotive safety grade pressure sensors require metal fasteners and manual installation, which are costly and time-consuming, and do not allow for a compact sheet metal pattern, limiting the size and cost reduction of sensor assemblies.
Innovation Solution
A sensor assembly with a housing that linearly slides relative to another portion, utilizing a hooked locking feature and guiding tab for secure attachment to sheet metal without fasteners, allowing for a smaller sheet metal pattern and reduced costs, while ensuring environmental sealing and electrical connection integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal fasteners and manual installation methods are used for attaching pressure sensors, then reliable attachment is achieved, but installation cost and time increase
Solution Approach 1:
The patent replaces traditional metal fastener systems with a plastic housing integration system. The sensor housing is molded with integrated engaging members (ribs, tabs, grooves) that mechanically interlock with the bracket, eliminating the need for separate metal fasteners while maintaining attachment reliability and enabling faster installation.
Solution Approach 2:
The patent combines the fastening function into the housing structure itself. The engaging members are integrated into the housing during molding, merging the structural housing function with the fastening function, thereby eliminating separate fastener components and reducing installation steps.
2Reliability
If traditional mounting methods are used, then secure attachment is achieved, but sheet metal pattern size increases
Solution Approach 1:
The patent segments the attachment function into multiple distributed engaging members (ribs, tabs, grooves) that are integrated into the housing. These segmented features distribute the attachment load across multiple points, providing secure attachment with a more compact footprint on the sheet metal bracket.
Solution Approach 2:
The engaging members are nested within the housing structure itself rather than requiring separate external fasteners. The ribs and tabs are molded into the housing cavity walls, creating a compact integrated attachment system that reduces the overall mounting footprint on the sheet metal.
3Productivity
If integrated engaging members are used for fastenerless installation, then installation cost and time are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The engaging members are pre-formed and precisely positioned during the housing molding process. The ribs, tabs, and grooves are created with precise dimensions and locations as integral parts of the molded housing, ensuring proper alignment before assembly occurs. This preliminary formation during molding eliminates the need for post-molding alignment adjustments.
Solution Approach 2:
The housing structure itself provides the alignment features through its molded geometry. The engaging members are designed with self-aligning characteristics where the molded ribs and grooves naturally guide proper positioning during assembly, eliminating the need for external alignment tools or complex adjustment procedures.
Data Source
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AI summary
A mountable sensor assembly for mounting on the sheet metal of a vehicle assembly. The sheet metal may have an opening for mounting the mountable sensor assembly. The mountable sensor assembly may include a sensor circuit and a sensor housing assembly. The sensor housing assembly may include a first portion with a cavity that receives the sensor circuit and a second portion that slideably interacts with the first portion to lock the sensor housing into the opening in the sheet metal.