Tire Sensor Housing With Replaceable Battery Through Rubber
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Solution Overview
Problem
Existing rubber-embedded sensors in tires are limited by the lifespan of their power sources, which is a critical issue affecting their functionality and reliability.
Innovation Solution
A partially embedded sensor apparatus is integrated into the tire's innerliner, featuring a power source housing with a removable cover and a flexible printed circuit board, secured by flanges and rubber interlocks, allowing for secure placement and protection from debris and water, with a battery inserted post-curing to ensure durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a power source is embedded in rubber for a tire sensor, then the sensor can be integrated into the tire structure, but the sensor's lifespan is limited by the power source duration
Solution Approach 1:
The sensor system is divided into separate functional modules: the sensing elements embedded in the tire, the power source housed in a separate housing, and the communication antenna. This segmentation allows the power source to be replaced independently without replacing the entire sensor system, thereby extending the operational lifespan while maintaining reliability.
Solution Approach 2:
The patent implements a replaceable power source design where the battery can be discarded after depletion and replaced through the removable housing. This allows the sensor system to be recovered and continue functioning, effectively extending the overall lifespan of the sensor while maintaining reliable operation through fresh power sources.
2Ease of manufacture
If electrical components are exposed in the tire sensor, then the sensor can be simpler to manufacture, but the components are vulnerable to debris and water
Solution Approach 1:
The electrical components including the power source, circuit board, and antenna are nested within a protective housing that is itself integrated into the tire structure. This nested design provides multiple layers of protection against debris and water while maintaining manufacturing efficiency through modular assembly.
Solution Approach 2:
The protective housing and seal components are designed as simple, cost-effective elements that can be easily replaced if damaged, providing robust protection against environmental harmful factors without significantly increasing manufacturing complexity or cost.
3Reliability
If the sensor is fully embedded in the tire, then the sensor is protected from damage, but the power source lifespan limits the sensor functionality
Solution Approach 1:
The sensor system is segmented into permanently embedded sensing elements and a replaceable power source module. This allows the protected embedded portion to remain intact while the power source is periodically replaced, extending the overall lifespan without compromising the protection of the sensitive components.
Solution Approach 2:
The system transitions from a static embedded design to a dynamic architecture where the power source can be accessed and replaced. The removable housing and access mechanisms enable this dynamic interaction, allowing the sensor to maintain its protected embedded state while enabling power source replacement to extend functionality.
Data Source
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AI summary
A tire-sensor-system is disclosed comprising: a sensor positioned in an interior of a tire, the sensor including a power source housing, wherein at least a portion of the sensor interlocks with a rubber portion of a tire, wherein the power source housing is disposed on an interior surface of the tire and wherein the power source housing is fastened to the portion of the sensor through the rubber portion; and at least one electrical conductor between the power source housing and the portion of the sensor, the at least one electrical conductor extending through the rubber portion. Also, a method is disclosed providing a sensor comprising a power source housing attached to a printed circuit board; interlocking a portion of the sensor with green rubber within a green tire such that at least a portion of the power source housing is exposed in an axially inward direction of the green tire; and curing the green tire after the interlocking of the portion of the sensor with the green rubber. Finally, an apparatus is provided comprising a sensor interlocked in rubber, the sensor including a power source housing, wherein at least a portion of the power source housing protrudes through the rubber.