Substrate-Free Buckle Switch Structure for Compact Latch Detection
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Solution Overview
Problem
Existing seat belt buckle switches have a large volume due to the inclusion of a substrate with a magnetic sensor, which increases the overall size of the buckle.
Innovation Solution
The buckle switch integrates a magnetic sensor directly onto a synthetic resin mold without a substrate, with a movable magnet and ejector mechanism to detect tongue insertion, reducing the volume by eliminating the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a substrate is used to mount the magnetic sensor in the buckle switch, then the magnetic sensor can be properly supported and connected, but the volume of the buckle switch and buckle increases
Solution Approach 1:
The invention extracts and eliminates the substrate from the buckle switch structure. Instead of mounting the magnetic sensor on a substrate, the sensor is directly integrated into the housing, removing the unnecessary component and reducing overall volume while maintaining functional integrity
Solution Approach 2:
The invention merges the magnetic sensor mounting function directly into the housing structure. The housing simultaneously serves as both the structural enclosure and the sensor mounting platform, eliminating the need for a separate substrate and reducing the number of parts
2Measurement precision
If a substrate is included in the buckle switch structure, then the magnetic sensor can be properly positioned, but the overall buckle size becomes large
Solution Approach 1:
The substrate is extracted from the structure, and the housing directly provides the positioning function. The magnetic sensor is mounted directly on the housing with precise positioning features that eliminate the need for a separate substrate while maintaining detection accuracy
Solution Approach 2:
The housing is designed to serve multiple functions: it encloses the magnetic sensor, provides structural support, and enables precise positioning of the sensor relative to the magnet. This multi-functionality eliminates the need for a separate substrate while maintaining measurement precision
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 configuration allows for a compact buckle switch and buckle design, reducing the overall volume while maintaining functionality.
Implementation Method 1
a magnetic sensor that detects a latch in response to magnetic flux of a magnet moving accompanying tongue insertion
Data Source
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AI summary
A buckle switch 20 includes a magnetic sensor for detecting the latch of a tongue plate 6. The magnetic sensor is installed inside a sensor chip 21. The sensor chip 21 is disposed above a synthetic-resin base mold 31. A top mold 32 is formed by insert molding. There is no circuit substrate in the buckle switch 20.