Sensor Device Metal Terminal Positioning via Protrusions

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Solution Overview

Problem

Existing sensor devices face challenges in achieving high positioning accuracy for metal terminals during the molding process due to difficulties in inserting and aligning them correctly within a die, leading to variations in pin height and potential deformation.

Innovation Solution

The sensor device incorporates protruding portions on the metal terminals that are aligned differently from the axial direction, allowing for accurate insertion and positioning by pressing down these protrusions, which improves workability and reduces deformation risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal terminals are inserted into a molding die for resin molding, then the housing portion can be formed with integrated support for detector and terminals, but positioning accuracy of the metal terminals becomes difficult to ensure due to alignment difficulties

Engineering Contradiction:

Improveintegrated molding of housing portionVSAvoidpositioning accuracy of metal terminals

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Positioning protrusions are introduced as intermediary elements between the metal terminals and the molding die. These protrusions engage with corresponding positioning grooves in the die to establish precise positioning relationships, mediating the alignment between terminal leading ends and the die cavity without requiring direct complex alignment of the terminals themselves

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The positioning protrusions are pre-formed on the metal terminals before insertion into the molding die. This preliminary formation of positioning features ensures that when the terminals are inserted, the alignment is automatically established through the engagement of protrusions with positioning grooves, eliminating the need for complex real-time alignment procedures

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If metal terminals are aligned in the axial direction for connector termination, then connector assembly is simplified, but positioning accuracy during molding deteriorates due to difficulty in pressing and aligning within the die

Engineering Contradiction:

Improveconnector assembly simplicityVSAvoidpin height accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The positioning protrusions extend in a direction different from the axial direction of the connector terminals. This dimensional change allows the protrusions to engage with positioning grooves in a direction perpendicular to the terminal insertion direction, providing stability and positioning accuracy without interfering with the axial alignment required for connector assembly

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS9116021B2Sensor device

Publication Date: 2015.08.25 MITSUBISHI ELECTRIC MOBILITY CORP

AI summary

A sensor device includes a detector portion, plural metal terminals that transmit a detection signal from the detector portion, and a housing portion, which integrally supports the detector portion and metal terminals, formed from resin, leading end portions of the plural metal terminals configuring connector terminals, and the plural metal terminals being disposed with at least one portion thereof aligned when seen from the axial direction of the connector terminals, wherein protruding portions protruding in a direction differing from the axial direction of the connector terminals are provided on the metal terminals.