Automotive Sensor Protector Sealing via Dual Injection Molding
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Solution Overview
Problem
Existing methods for molding terminal parts of protectors with sensors in automobiles result in uneven shapes and inadequate sealing, often requiring additional processes like adhesive application or extra members, which increase costs and complexity.
Innovation Solution
The use of a primary and secondary sealing layer formed by injection molding, where the primary sealing layer coats the wire connection parts and insert, and the secondary sealing layer forms the external shape, using rubber-like elastic materials like EPDM and TPO to ensure stable and uniform sealing without the need for adhesives or extra members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive application or extra members are used to seal terminal parts, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the sealing function with the existing terminal part structure by forming sealing layers directly on the terminal parts through injection molding. The sealing layers are integrated with the terminal parts as a unified structure, eliminating the need for separate adhesive application processes or additional sealing members. This merging approach maintains high sealing reliability while reducing device complexity.
Solution Approach 2:
The terminal parts perform their own sealing function through the injection-molded sealing layers that are formed directly on their surfaces. The sealing structure is self-contained and does not require external adhesive applications or separate sealing components. The terminal parts with integrated sealing layers serve both their electrical connection function and sealing function simultaneously.
2Reliability
If adhesive application or extra members are used to seal terminal parts, then sealing reliability is improved, but manufacturing time and operational time increase
Solution Approach 1:
The sealing layers are formed on the terminal parts during the injection molding process itself, before any subsequent assembly or installation steps. This preliminary formation of sealing layers eliminates the need for separate adhesive application and curing processes that would otherwise be required after assembly, significantly reducing total manufacturing time while ensuring sealing reliability from the outset.
Solution Approach 2:
The sealing process is merged with the injection molding process, allowing both the terminal parts and sealing layers to be formed in a single operational step. This consolidation of processes eliminates multiple sequential steps (molding, then adhesive application, then curing) and reduces overall manufacturing time while maintaining high sealing reliability.
3Ease of manufacture
If conventional molding methods are used for terminal parts, then manufacturing simplicity is maintained, but shape uniformity and sealing quality deteriorate
Solution Approach 1:
The patent applies specific injection molding parameters and conditions to form the sealing layers on the terminal parts. By controlling parameters such as injection pressure, temperature, and molding cycle, the process achieves uniform shape and high sealing quality. The rubber-like elastic materials used respond predictably to these parameter changes, ensuring consistent results while maintaining manufacturing simplicity through a single-process approach.
Solution Approach 2:
The injection molding process applies localized quality control to the terminal parts by forming sealing layers with specific properties in specific locations. The sealing layers are formed only where needed on the terminal parts, with controlled thickness and material properties, ensuring uniform shape and high sealing quality in critical areas while maintaining overall manufacturing simplicity.
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
This approach enhances the sealing properties, reduces operational time, and ensures uniformity in product shape and size, improving productivity and preventing unevenness, while maintaining adhesion and heat resistance.
Implementation Method 1
a primary sealing layer and a secondary sealing layer formed by injection molding
Implementation Method 2
using rubber-like elastic materials like EPDM and TPO
Implementation Method 3
maintaining adhesion and heat resistance
Implementation Method 4
maintaining adhesion and heat resistance
Data Source
AI summary
A protector with a sensor is installed on a sliding door for detecting an alien substance by touch between two core wires in a hollow part. In a terminal part of the protector with the sensor, the core wires drawn out are connected with a resistor or leads joined with a control unit. A primary seal is formed by injection molding for coating wire connection parts and another end side of an insert and a secondary seal is formed by the injection molding for coating a part formed with the primary seal for forming an external shape of a product.