Resin Encapsulated Sensor Terminal Positioning

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Solution Overview

Problem

The lack of rigidity in metal terminals in in-vehicle sensors makes it difficult to maintain positional accuracy during molding, leading to handling challenges and reduced productivity, as well as potential deformation during exterior molding.

Innovation Solution

An insulating fixing portion is used to hold multiple metal terminals separately, providing rigidity and allowing for easier handling and improved positional accuracy by gripping the fixing portion during fabrication, and stabilizing the metal terminals within the die during molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple metal terminals are inserted into the die simultaneously, then productivity is improved, but the lack of rigidity makes it difficult to maintain positional accuracy

Engineering Contradiction:

ImproveproductivityVSAvoidpositional accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The metal terminals are segmented into individual units, each with its own insertion hole in the die, allowing simultaneous insertion while maintaining positional control through separate positioning features

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Positioning protrusions and positioning holes act as intermediary elements between the metal terminals and the die, ensuring accurate positioning during simultaneous insertion while the resin material provides structural support

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If metal terminals are handled by gripping, then ease of operation is improved, but the lack of rigidity makes handling difficult

Engineering Contradiction:

Improvehandling easeVSAvoidrigidity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The handling structure is segmented into individual gripping portions for each metal terminal, allowing independent manipulation while the overall assembly provides structural support through the resin material

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The resin material acts as a flexible shell that provides structural support to the metal terminals, enabling easy handling through the gripping portions while maintaining rigidity where needed

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If the metal terminals are inserted with insufficient insertion amount, then ease of manufacture is improved, but accuracy of pin height cannot be obtained

Engineering Contradiction:

Improveease of manufactureVSAvoidpin height accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Positioning protrusions and positioning holes are provided in advance in the die to ensure accurate positioning of metal terminals before resin injection, guaranteeing pin height accuracy while simplifying the manufacturing process

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9429451B2Sensor with resin encapsulated terminal separation

Publication Date: 2016.08.30 MITSUBISHI ELECTRIC MOBILITY CORP

AI summary

A sensor includes: a sensing module furnished with a sensing function; metal terminals transmitting a sensing signal from the sensing module; an insulating fixing portion holding multiple metal terminals separately; and a resin portion encapsulating the metal terminals and the sensing module and also forming a connector portion from which tip ends of the metal terminals are exposed. Protruding portions of the fixing portion are fit into hole portions of the metal terminals before resin encapsulation in a stage where the metal terminals are bonded to the sensing module, so that rigidity of the metal terminals is enhanced to stabilize the locations thereof.