Sensor Module Fused Connection for Positioning and Encapsulation
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Solution Overview
Problem
Existing sensor modules face challenges in achieving reliable encapsulation while maintaining ease of production and easy positioning and fastening, particularly in environments with significant dimensional tolerances and mechanical stress.
Innovation Solution
A sensor module design featuring a sensor unit, a sensor cover, and a main body connected via a fused connection, preferably through laser or ultrasonic welding, allowing for precise positioning and integral component formation without separate mounts, enabling reliable encapsulation and compensation for dimensional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is completely enclosed in a protective material, then the sensor protection from ambient conditions is improved, but the positioning precision and fastening complexity deteriorate
Solution Approach 1:
The sensor module is divided into three distinct components: sensor unit, sensor cover, and main body. This segmentation allows each component to be optimized independently - the sensor unit for protection, the sensor cover for encapsulation, and the main body for positioning - thereby resolving the contradiction between protection and positioning precision.
Solution Approach 2:
The sensor cover acts as an intermediary component between the sensor unit and the external environment. It provides the protective encapsulation while its specific geometric design (with base surface and projection) serves as the interface for precise positioning and fused connection to the main body, thus maintaining positioning precision while achieving protection.
2Reliability
If the sensor is completely enclosed in a protective material, then the sensor protection from ambient conditions is improved, but the production ease deteriorates
Solution Approach 1:
By segmenting the sensor module into pre-assembled units (sensor unit with sensor cover) and a main body, the production process is simplified. Each segment can be manufactured and prepared independently, then quickly joined through fused connection, improving overall production ease while maintaining protection.
Solution Approach 2:
The traditional mechanical fastening system (screws, clips, adhesives) is replaced by a fused connection method. This substitution eliminates complex assembly steps and fastening mechanisms, making production easier while ensuring reliable protection through the integrated fused structure.
3Adaptability or versatility
If separate mounts are used for fastening the sensor, then the positioning flexibility is improved, but the device complexity increases
Solution Approach 1:
The positioning function and the protective encapsulation function are merged into the sensor cover itself. The sensor cover's geometric features (base surface, projection) provide both structural support for positioning and protective enclosure, eliminating the need for separate mounts and reducing overall device complexity.
Solution Approach 2:
The sensor cover serves multiple functions simultaneously: it protects the sensor unit, provides positioning features through its base surface and projection, and enables fused connection to the main body. This multi-functionality replaces what would otherwise require separate components, reducing complexity while maintaining positioning flexibility.
4Adaptability or versatility
If dimensional tolerances are significant, then the manufacturing adaptability is improved, but the positioning precision deteriorates
Solution Approach 1:
The design allows for selectable relative positioning between the main body and sensor cover, meaning the positional parameters can be adjusted within certain ranges to accommodate dimensional tolerances. This parameter flexibility enables manufacturing adaptability while maintaining sufficient positioning precision through the fused connection geometry.
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 solution provides a robust, easily integratable sensor module with reliable encapsulation and precise positioning, capable of handling dimensional tolerances and mechanical stress, without compromising the integrity of the sensor, and allowing for direct integration into larger structural units.
Implementation Method 1
The sensor cover is connected to at least one out of the base surface and the main body by way of a fused connection. The main body is connected at least to the base surface of the sensor unit by way of a fused connection with a selectable relative position in relation to the sensor cover.
Implementation Method 2
The sensor cover is connected to at least one out of the base surface and the main body by way of a fused connection. The main body is connected at least to the base surface of the sensor unit by way of a fused connection with a selectable relative position in relation to the sensor cover.
Data Source
AI summary
A sensor module contains a sensor unit, a sensor cover, and a main body. The sensor unit has a sensor surface and a base surface. The sensor cover covers the sensor surface and at least a section of the base surface. The sensor cover is connected to the base surface and/or the main body by a fused connection. The main body is connected at least to the base surface of the sensor unit by a fused connection with a selectable relative position in relation to the sensor cover. Pre-mounting of the sensor unit in a sensor cover and advantageous encapsulation of a sensor can thus be achieved.