Terminal-Integrated Sensor Assembly Housing Design
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Solution Overview
Problem
Conventional automotive sensors face difficulties in making electrical and mechanical connections between sensor circuits and terminals, particularly when terminals are integrated into the sensor packages, making integration into housing assemblies challenging.
Innovation Solution
A device with a terminal-containing sensor assembly that includes a package with integrated terminals, a housing assembly with specific cavities and ports for terminal extension, and deformable ribs or welding techniques for secure attachment, allowing for precise positioning and sealing within a motor vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are integrated into sensor packages before mounting into housing assemblies, then electrical connection between sensor circuits and terminals is improved, but integration of sensor packages into housing assemblies becomes difficult
Solution Approach 1:
The housing assembly is divided into multiple cavities: a first cavity for receiving the sensor assembly and a second cavity for receiving the electrical connector. This segmentation allows the sensor package with integrated terminals to be mounted separately and then connected to the electrical connector through ports, resolving the contradiction between reliable electrical connection and ease of integration.
Solution Approach 2:
Ports are introduced as intermediary elements that extend from the first cavity to the second cavity. These ports allow the terminals to pass through and establish electrical connection between the sensor assembly and the electrical connector, enabling both reliable electrical connection and easy integration into the housing assembly.
2Ease of manufacture
If conventional stitching method is used to connect sensor circuits to terminals, then manufacturing process is simple, but mechanical connection reliability deteriorates
Solution Approach 1:
The terminals are merged with the sensor package as an integrated unit, and the electrical connector is merged with the housing assembly. This combining eliminates the need for separate stitching operations and creates robust mechanical connections through the integrated structure and port-based connection system.
Solution Approach 2:
The terminals are pre-integrated into the sensor package before mounting into the housing assembly. This preliminary integration ensures proper alignment and reduces the complexity of subsequent connection steps, improving both manufacturing ease and connection reliability.
3Stability of the object's composition
If sensor assembly is securely attached in housing assembly, then mechanical stability is improved, but manufacturing complexity increases
Solution Approach 1:
The housing assembly is segmented into functional cavities and the attachment mechanism is segmented into ribs that can be independently formed during molding. This segmentation allows for simplified manufacturing of each component while achieving stable assembly through the integrated rib structure.
Solution Approach 2:
The ribs are designed to automatically engage with the sensor assembly during the molding process, providing self-aligning and self-securing functionality. This self-service mechanism reduces the need for additional attachment steps and tools, maintaining manufacturing simplicity while ensuring mechanical stability.
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 solution enables easy integration of sensor assemblies with integrated terminals into housing assemblies, providing a low-cost, efficient manufacturing process with reduced cycle times and bill-of-materials, while ensuring secure attachment and environmental sealing.
Implementation Method 1
At least one rib may apply at least one force on the sensor assembly to hold the sensor assembly in the first cavity
Data Source
AI summary
An apparatus includes a sensor assembly and a housing assembly. The sensor assembly may have (i) a package surrounding a sensor and (ii) a plurality of terminals integrated with the package. The housing assembly may have (i) a first cavity configured to receive the sensor assembly, (ii) a second cavity configured to receive an electrical connector, (iii) a plurality of ports in communication between the first cavity and the second cavity and (iv) a location feature configured to orient the housing assembly while the housing assembly is mounted to a structure. At least one rib may apply at least one force on the sensor assembly to hold the sensor assembly in the first cavity. The sensor may be outside a plane of the force. The terminals may extend through the ports from the first cavity to the second cavity.