Laser-Welded Sensor Module Structure for Resin Burr Suppression
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Solution Overview
Problem
Existing sensor module designs face challenges in miniaturization due to the need for space to accommodate grooves and stepped structures for laser welding, which also require precise laser positioning, leading to resin burrs and reduced workability.
Innovation Solution
A sensor module design with grooves formed in the welded regions of the cases to accommodate melted resin, allowing for seamless integration and reduced protrusion, and using laser-absorptive and transmissive resin materials to enhance weld strength and minimize appearance defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If grooves are formed on both sides of the scanning locus to accommodate melted resin, then resin burrs are suppressed, but the joining surface area increases and miniaturization is hindered
Solution Approach 1:
The groove is positioned on the inner peripheral side of the scanning locus rather than on both sides, utilizing the inner dimension space to accommodate melted resin. This dimensional repositioning reduces the required joining surface area while still preventing resin burr formation on the outer peripheral side.
Solution Approach 2:
The groove is strategically placed only where needed (inner peripheral side of scanning locus) rather than uniformly on both sides. This localized approach maintains resin containment functionality while minimizing the total joining surface area required.
2Object-generated harmful factors
If a stepped structure is provided on the outer peripheral side to form welded portion, then resin burrs are suppressed, but the product size increases
Solution Approach 1:
Instead of using a stepped structure that extends the product outward, the groove is positioned on the inner peripheral side, utilizing internal space rather than external expansion. This reduces the overall product volume while maintaining resin containment.
Solution Approach 2:
The groove is nested within the inner peripheral region of the scanning locus, utilizing existing structural space rather than adding external volume. This allows resin accommodation without increasing product dimensions.
3Object-generated harmful factors
If grooves or stepped structures are provided, then resin burrs are suppressed, but precise laser positioning is required reducing workability
Solution Approach 1:
The groove is pre-formed on the inner peripheral side of the scanning locus before welding. This preliminary structural preparation guides the melted resin flow automatically during welding, reducing the need for precise laser positioning adjustments while still preventing resin burrs.
Solution Approach 2:
The groove structure automatically contains and directs the melted resin during the welding process without requiring additional control mechanisms or precise positioning adjustments. The structure serves its own resin containment function passively.
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 suppresses resin burrs, improves workability by eliminating the need for precise laser positioning, and reduces product size while maintaining robust weld strength.
Implementation Method 1
a front case and a rear case are joined to each other using welding by irradiation of laser light
Implementation Method 2
the melted resin generated by the irradiation of laser light
Implementation Method 3
an absorbent resin material that absorbs laser light
Data Source
AI summary
[Object] To provide a sensor module that makes it possible to suppress generation of resin burrs and improve workability.[Solving Means] A sensor module (100) according to an embodiment of the present technology includes a sensor element, a first case (11), a second case (12), and a groove (70). The first case (11) includes an opening end including a first welded region and accommodates therein the sensor element. The second case (12) includes a joining surface (123) including a second welded region (50), the second welded region (50) being welded to the first welded region to form a welded portion. The groove (70) is formed in at least one of the first welded region or the second welded region (50).