Spring Clip Sensor Mounting Eliminates Metal Bushing Cost
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Solution Overview
Problem
The high cost of crash sensor assemblies is driven by the integrated metal bushing, which incurs material and machining costs, and requires specific manufacturing, limiting cost reduction and manufacturing flexibility.
Innovation Solution
A sensor assembly with a spring clip that locks a spreadable retention post to the vehicle sheet metal, eliminating the need for a bushing by using a plastic retention post with a barbed cantilever and ratcheting interface, and a spring clip that expands the post's perimeter for secure retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrated metal bushing is used for mounting the sensor assembly, then the mounting structure is stable and reliable, but the production cost increases and manufacturing flexibility decreases
Solution Approach 1:
The patent removes the integrated metal bushing from the mounting structure and replaces it with a separate spring clip component. This extraction eliminates the need for expensive metal bushings while maintaining mounting reliability through the spring clip's elastic retention mechanism.
Solution Approach 2:
The patent changes the material parameter from metal bushing to plastic housing with spring clip, and changes the mounting mechanism parameter from rigid interference fit to elastic spring-loaded retention. This parameter change reduces cost while maintaining reliability through the spring's continuous retention force.
2Reliability
If an integrated metal bushing is used for mounting the sensor assembly, then the mounting structure is stable and reliable, but the manufacturing complexity increases and manufacturer options decrease
Solution Approach 1:
The patent segments the mounting function into two separate components: the plastic housing and the spring clip. This segmentation simplifies manufacturing by allowing each component to be produced independently through simpler processes, while the assembly of these segments provides the reliable mounting function.
Solution Approach 2:
The spring clip provides self-service by automatically adjusting to the sheet metal opening and providing continuous retention force through its elastic properties. This eliminates the need for complex precision machining and assembly procedures required for metal bushings.
3Reliability
If a bushing and bolt mounting system is used, then the mounting is secure, but the assembly weight increases and assembly ease decreases
Solution Approach 1:
The patent removes the bolt from the mounting system and replaces it with a spring clip that provides retention through elastic force. This extraction eliminates the heavy metal bolt while maintaining secure mounting through the spring's continuous retention force on the retention post.
Solution Approach 2:
The patent uses composite construction with a plastic housing and spring clip instead of all-metal bushing and bolt assembly. This composite approach significantly reduces weight while maintaining mounting security through the spring's elastic retention mechanism.
4Reliability
If a bushing and bolt mounting system is used, then the mounting is secure, but the assembly cost increases and assembly ease decreases
Solution Approach 1:
The patent segments the mounting function into a spring clip and retention post system that can be assembled through simpler processes. The spring clip can be independently manufactured and then assembled to the housing, reducing overall assembly cost and complexity while maintaining secure mounting.
Solution Approach 2:
The patent changes the retention mechanism from mechanical fastening with bolts to elastic retention with spring clips. This parameter change eliminates the need for precision threading and bolt tightening procedures, reducing assembly cost and complexity while maintaining mounting security.
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
This solution reduces production costs, allows sourcing from a wider range of manufacturers, and provides a reliable retention force over the sensor's life, making the assembly lighter and easier to assemble while maintaining secure attachment.
Implementation Method 1
A clip may be configured to lock onto the mounting post and extend into the gap to expand a perimeter of the mounting post
Data Source
AI summary
A mountable sensor assembly for mounting on the sheet metal of a vehicle assembly. The sheet metal may have an opening for mounting the mountable sensor assembly. The mountable sensor assembly may include a sensor circuit, a sensor housing with a mounting post, and a clip. The sensor housing may include a cavity that receives the sensor circuit. The sensor housing may include a mounting surface and a mounting post extending from the mounting surface. The mounting post may include a gap allowing the diameter of the post to expand and contract. A clip is configured to lock onto the mounting post and extend into the gap to expand a perimeter of the mounting post. By expanding the perimeter, the mounting post is locked through the opening in the sheet metal.