Foreign Object Detection Sensor Spacer Segmentation

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Solution Overview

Problem

The existing terminal portion molding method for foreign object detection sensors faces challenges with spacer insertion due to the H-shaped cross-section of the spacer, leading to deteriorated workability and potential displacement during injection molding, which exposes core wires and affects insulation.

Innovation Solution

A spacer with an elongated hollow sheath and conductive members, featuring a first member with an insertion portion and a concave-shaped second member with a locking portion, is used to improve workability and insulation by locking the conductor portions within a closed cross-section during injection molding, preventing displacement and ensuring electrical insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the spacer has an H-shaped cross-section to position core wires, then positioning function is improved, but workability deteriorates due to difficult insertion

Engineering Contradiction:

Improvepositioning accuracyVSAvoidinsertion workability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The spacer is divided into two separate members: a first member with an insertion portion that fits into the space between conductive members, and a second member with a locking portion that locks to the first member. This segmentation allows the first member to be easily inserted without the complex H-shape, while the second member adds positioning functionality through locking, thus resolving the contradiction between insertion ease and positioning accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first member is inserted into the space between conductive members before the second member is attached. This preliminary insertion action allows the basic positioning structure to be in place first, and then the locking function is added subsequently, making the overall process more workable than trying to insert a pre-formed H-shaped structure.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If injection molding is performed with the H-shaped spacer, then terminal portion molding is completed, but spacer displacement occurs due to injection pressure exposing core wires

Engineering Contradiction:

Improvemolding efficiencyVSAvoidinsulation reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The second member is designed to be rotatable relative to the first member around a hinge point. During injection molding, this rotational capability allows the spacer structure to dynamically adjust and absorb injection pressure, preventing displacement that would expose core wires and compromise insulation reliability, while still maintaining molding efficiency.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If the spacer structure is simplified for easy insertion, then workability is improved, but positioning and insulation performance deteriorates

Engineering Contradiction:

Improveinsertion workabilityVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The first member and second member are merged through a locking mechanism where the locking portion of the second member engages with the first member. This merging combines the easy insertion capability of the first member with the positioning accuracy of the second member, achieving both workability and positioning precision simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

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 workability and prevents displacement of conductor portions during injection molding, ensuring effective electrical insulation and improved reliability of the foreign object detection sensor terminal portion.

Implementation Method 1

an integral hinge portion (53) about which the second member (54) is rotatable with respect to the first member (52)

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10821641B2Spacer for foreign object detection sensor and terminal portion molding method of foreign object detection sensor

Publication Date: 2020.11.03 AISIN SEIKI KK

AI summary

A spacer for a foreign object detection sensor including an elongated hollow sheath, two conductive members, and two core wires buried in the two conductive members, the spacer being used for a terminal portion of the foreign object detection sensor and including a first member including an insertion portion configured to be inserted into a space between the two conductive members, and a concave-shaped second member including a first end portion and a second end portion, the first end portion at which a locking portion is provided to be locked to a first end of the first member, the second end portion which is opposed to the locking portion and is connected to a second end of the first member via an integral hinge, the second member containing one of the two conductor portions inside a closed cross-section formed between the first member and the second member.