Sensor Unit Manufacturing Method for Tail Gate Systems
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Solution Overview
Problem
Conventional sensor units for automatic tail gate systems face issues with appearance deterioration and positional adjustment difficulties due to hard resin and core metal components, leading to reduced yield and versatility.
Innovation Solution
A sensor unit manufacturing method that includes a core metal insertion process and a bending process to adjust the position of the curving portion, allowing for improved appearance and positional flexibility of the sensor holder, enabling precise fixation and increased versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a hard resin portion having a hardness higher than the hardness of the base portion is arranged, then the base portion can be held in a curved state to prevent double-sided tape peeling, but a boundary section between the base portion and the hard resin portion becomes conspicuous causing appearance deterioration
Solution Approach 1:
The patent extracts the hard resin portion from the base portion structure and replaces it with a separate core metal member inserted into a dedicated accommodation portion. This separation eliminates the boundary section problem between hard resin and base portion, as the core metal is accommodated within a hollow space rather than being integrated into the base portion material, thus preventing appearance deterioration while maintaining the curved state stability function.
2Stability of the object's composition
If a core metal is molded in a section of the base portion which corresponds to the curving portion, then the base portion can be held in a curved state, but the section swells due to shrinkage of the insulating rubber material causing appearance deterioration
Solution Approach 1:
The patent segments the base portion by creating a hollow core metal accommodation portion within it. Instead of molding core metal directly into the base portion material (which causes swelling), the base portion is designed with a dedicated cavity that accommodates the core metal member. This segmentation prevents the swelling issue while allowing the base portion to maintain its curved shape stability.
3Stability of the object's composition
If the position of the hard resin portion or core metal is fixed in the injection molding process, then the base portion can be held in a curved state, but positional deviation cannot be adjusted leading to yield deterioration and reduced versatility
Solution Approach 1:
The patent introduces adjustability into the system by allowing the core metal member to be inserted into the core metal accommodation portion at various positions along the longitudinal direction. Unlike the fixed position in injection molding, the core metal can be repositioned to adjust the curving portion location, enabling adaptation to different vehicle types and preventing yield loss due to positional deviations.
4Stability of the object's composition
If the position of the hard resin portion or core metal is fixed in the injection molding process, then the base portion can be held in a curved state, but the sensor unit cannot be made common with other vehicle types reducing versatility
Solution Approach 1:
The patent enables versatility by allowing dynamic adjustment of the core metal member position within the core metal accommodation portion. The core metal can be inserted at different longitudinal positions to create curving portions at various locations, allowing the same sensor holder to be adapted to different vehicle types and applications, thereby improving universality and reducing the need for multiple specialized components.
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 method enhances the appearance and adjustability of the sensor unit's curving portion, improving yield and versatility by allowing for precise positioning and reduced visibility of the core metal, thus addressing the limitations of existing technologies.
Implementation Method 1
a sensor holder which holds the sensor main body and is elastically deformed by application of an external force
Implementation Method 2
a bending process of bending the section of the fixation base portion, into which the core metal member is inserted, following a curved shape of the fixation object
Data Source
AI summary
A sensor unit manufacturing method includes: a core metal insertion process of inserting a core metal member having a length dimension smaller than a length dimension of a core metal accommodation portion into a predetermined location (a section of a curving portion) extending along a longitudinal direction of the core metal accommodation portion; and a bending process of bending the section (the section of the curving portion) of a fixation base portion, into which the core metal member is inserted, following a curved shape of a sensor bracket.