Sensor Sheet Mounting Plate Structure for Accurate Curved Surface Assembly
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Solution Overview
Problem
The existing sensor sheet-containing exterior components face challenges with poor workability due to the sensor sheet being easily bent when bonded to exterior members with protrusions and recesses, and the difficulty in separating the sensor sheet from the exterior member, leading to the need for replacing both components if a fault is detected.
Innovation Solution
A sensor sheet-containing exterior component design that includes a mounting plate with a front surface shape corresponding to the back surface of the exterior member, along with a sensor sheet-fixing unit between the mounting plate and the sensor sheet, allowing for accurate mounting and easy separation of the sensor sheet from the exterior member, utilizing elastic members to ensure close contact and prevent air layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sensor sheet is bonded directly to the back surface of the exterior member having protrusions and recesses, then the sensor sheet can be mounted on the exterior member, but the sensor sheet is easily bent and workability deteriorates
Solution Approach 1:
A mounting plate is introduced as an intermediary component between the sensor sheet and the exterior member. The mounting plate has a front surface that corresponds to the back surface shape of the exterior member, allowing it to engage with the protrusions and recesses. The sensor sheet is then bonded to the flat back surface of the mounting plate, preventing bending while maintaining easy mounting procedures.
2Reliability
If the sensor sheet is integrally formed with the exterior member using adhesive or double sided tape, then the sensor sheet is firmly fixed, but the sensor sheet cannot be easily separated for replacement
Solution Approach 1:
The system is divided into three separable components: the exterior member, the mounting plate, and the sensor sheet. The sensor sheet is bonded to the mounting plate, which in turn engages with the exterior member. This segmentation allows the sensor sheet to be easily separated from the exterior member by removing the mounting plate, enabling replacement without damaging the sensor sheet or exterior member.
3Manufacturing precision
If the sensor sheet is bonded to avoid overlapping protrusions and recesses, then bending is reduced, but mounting precision and workability deteriorate
Solution Approach 1:
The mounting plate serves as a mediator with a front surface designed to correspond to the back surface shape of the exterior member. This allows the mounting plate to engage with the protrusions and recesses, providing a flat bonding surface for the sensor sheet. The sensor sheet can be mounted with high precision on the flat back surface of the mounting plate without needing to avoid overlapping the protrusions and recesses of the exterior member.
Data Source
AI summary
A sensor sheet-containing exterior component includes an exterior member; a sensor sheet having a sensor electrode and disposed on a back surface of the exterior member; and a mounting plate that holds the sensor sheet in close contact with the exterior member, wherein the mounting plate has a front surface shape that substantially corresponds to a back surface shape of the exterior member and is configured to engage with the exterior member, and a sensor sheet-fixing unit is provided between the mounting plate and the sensor sheet so as to fix the sensor sheet to the mounting plate along the front surface shape of the mounting plate.