Load Detection Sensor Resin Bonding
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Solution Overview
Problem
Existing load detection sensors under seat cushions face durability issues due to bending and stretching caused by vibrations, leading to potential breaks, especially when the resin covering the connection part moves and applies stress to the sensor edges.
Innovation Solution
A load detection sensor unit with a sheet-like shape, featuring a pressure-sensitive element, a terminal electrically connected to the element, and a protective resin that is self-adhesively fixed to a support plate, preventing the resin from moving and reducing bending and stretching stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a load detection sensor is integrated into a toothbrush handle, then load detection capability is improved, but device complexity increases
Solution Approach 1:
The load detection sensor is integrated directly into the handle structure of the toothbrush, merging the sensing function with the existing mechanical structure. This eliminates the need for separate mounting components and reduces overall device complexity while maintaining load detection capability.
Solution Approach 2:
The handle structure serves multiple functions: it provides structural support, houses the load detection sensor, and transmits mechanical loads. By making the handle multi-functional, the patent avoids adding extra components that would increase device complexity.
2Reliability
If the sensor housing is filled with adhesive and embedding material, then reliability of sensor mounting is improved, but manufacturing complexity increases
Solution Approach 1:
The adhesive and embedding material are applied to the sensor housing before the sensor is installed. This preliminary preparation ensures proper positioning and secure mounting, improving reliability while simplifying the assembly process by pre-preparing mounting surfaces rather than requiring complex alignment procedures during assembly.
Solution Approach 2:
The adhesive serves as an intermediary material between the sensor housing and the sensor element, creating a reliable mechanical and thermal bond. This intermediate layer compensates for minor dimensional variations and ensures consistent sensor mounting without requiring precision machining or complex fastening mechanisms.
3Measurement precision
If the sensor is exposed to moisture and heat during use, then measurement precision may deteriorate, but protection structure adds device complexity
Solution Approach 1:
The sensor is nested within the sensor housing, which provides a protective enclosure. The housing is itself nested within the handle structure, creating layered protection. This nested arrangement protects the sensor from moisture and heat while using the existing hierarchical structure of the toothbrush, avoiding the need for additional external protection components.
Solution Approach 2:
The adhesive and embedding material serve as intermediary substances between the sensor and the housing environment. These materials provide thermal and moisture isolation, protecting the sensor from extreme conditions while maintaining mechanical coupling, thus preventing measurement deterioration without requiring complex protection structures.
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 enhances the durability of the load detection sensor unit by protecting the connection structure and preventing breaks under vibrating conditions, ensuring reliable operation.
Implementation Method 1
a sensor housing, the interior surface of which is covered with a layer of adhesive
Implementation Method 2
which is then covered with a layer of embedding material before the sensor is installed in the sensor unit and the adhesive and embedding material are allowed to set
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A load detection sensor unit 1 is disposed under a seat cushion SC, and includes a sheet-like load detection sensor 5 including a switch SW as a pressure sensitive element and a first terminal 56c and a second terminal 57c which are electrically connected to the switch SW, a support plate 2 on which the switch SW is mounted, and a protective resin 18 which covers the first terminal 56c and the second terminal 57c. The protective resin 18 is fixed to the support plate 2.