Injection-Molded Sensor Module Structure for Weld-Resistant Holes

The invention applies local quality by creating a coupling portion with locally increased thickness at the weld location. This thicker region concentrates the weld in a specific area that is structurally reinforced, while other portions of the article maintain their original thickness and properties. The localized thickness increase compensates for the potential weakness at the weld site by providing additional material and structural support precisely where needed.

The invention implements preliminary action by designing the mold to automatically create a thicker coupling portion at the expected weld location before the actual welding occurs. The mold geometry is configured in advance to guide the molten resin streams to join in this pre-determined thicker region, ensuring that the weld forms in a location that is structurally advantageous rather than allowing it to occur randomly in thinner, more vulnerable areas.

The invention applies local quality by creating a coupling portion with locally increased thickness at the weld location. This thicker region concentrates the weld in a specific area that is structurally reinforced, while other portions of the article maintain their original thickness and properties. The localized thickness increase compensates for the potential weakness at the weld site by providing additional material and structural support precisely where needed.

The invention converts the harmful effect of the weld (which normally creates weakness) into a beneficial outcome by directing it to form in a thicker coupling portion. The weld, instead of being a defect in a thin area, becomes a reinforced joint in a thickened region that can better withstand stresses. This transforms the unavoidable welding process from a source of rejection into a structurally acceptable feature.