Sensor Mounting Structure With Locking Tongue for Sink Mark Reduction
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Solution Overview
Problem
Existing receiving devices for attaching sensors in hot-molded polymer vehicle body panels suffer from sink marks and lack sufficient stability and holding force despite reduced wall thickness, compromising optical appearance and aesthetics.
Innovation Solution
A receiving device with a receiving section and deformable locking tongue, featuring a geometric flow aid section at the end of the locking tongue to stabilize the weld seam, and optional stiffening ribs, maintains a wall thickness of 0.8 mm to 1.8 mm to minimize sink marks while ensuring stability and holding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wall thickness of the receiving section and locking tongue is reduced to minimize sink marks, then the optical appearance and aesthetics are improved, but the stability and holding force for attaching the sensor deteriorate
Solution Approach 1:
The patent applies local quality by providing a geometric flow aid section at the end section of the locking tongue, while the rest of the locking tongue and receiving section maintain reduced wall thickness (0.8-1.8 mm). This localized structural enhancement stabilizes the weld seam above the locking element receiving without increasing the overall wall thickness, thus minimizing sink marks while ensuring adequate holding force at the critical welding location.
2Manufacturing precision
If the wall thickness is reduced to 0.8 mm to 1.8 mm to reduce sink marks, then the negative effect on visible side appearance is reduced, but the structural stability deteriorates
Solution Approach 1:
The geometric flow aid section is provided locally at the end section of the locking tongue in front of the locking element receiving, while the main body maintains thin wall thickness. This localized reinforcement stabilizes the weld seam without requiring increased wall thickness throughout the entire structure, achieving both sink mark reduction and structural stability.
Solution Approach 2:
Instead of increasing wall thickness (one-dimensional solution), the patent introduces a geometric flow aid section that modifies the three-dimensional structure at the end section of the locking tongue. This dimensional approach stabilizes the weld seam through geometric configuration rather than mass increase, maintaining thin walls while ensuring structural integrity.
3Quantity of substance
If the wall thickness is reduced to minimize polymer mass and sink marks, then the aesthetics are improved, but the holding force for sensor attachment is insufficient
Solution Approach 1:
The patent maintains minimal polymer mass throughout most of the receiving section and locking tongue (0.8-1.8 mm wall thickness) to reduce sink marks and polymer usage. The geometric flow aid section is added only at the critical end section where weld seam stabilization is needed, providing localized strength enhancement without significantly increasing overall polymer mass.
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 effectively reduces sink marks and enhances the optical appearance and stability of sensor attachment in vehicle body panels, maintaining structural integrity and aesthetic appeal.
Implementation Method 1
a geometric flow aid section (8) is provided as the end section (7) of the at least one locking tongue (5), in the insertion direction (S) of the sensor (10) in front of the respective locking element receiving (6), in order to stabilize a weld seam (9) above the locking element receiving (6)
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a receiving device for attaching a sensor (20) in the area of a continuous recess (1) in a hot-cast polymer vehicle trim part (2), wherein the receiving device consists of the vehicle trim part (2) and a sensor receptacle (3) formed integrally with the vehicle trim part (2).