Tubular Insulator Touch Sensor Preventing Resin Short Circuits
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional touch sensor units face issues with short circuits during the molding process due to molten resin flowing into the insulating tube, causing the linear electrodes to become fixed in a short-circuited state.
Innovation Solution
The manufacturing method involves a tubular insulator that is elastically deformed to prevent electrodes from being short-circuited, using an insulating member with an insertion protrusion inserted between the electrodes and a mold part design that includes the sensor holder, electrical component, and connection wire, where molten resin is supplied while the tubular insulator is pressed within a range where it overlaps with the insertion protrusion, preventing resin from entering the insulating tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molten resin is supplied into the mold during the molding process, then the mold part is successfully formed with waterproofing and protection functions, but the resin may flow into the insulating tube and cause the linear electrodes to short circuit
Solution Approach 1:
An insulating member (separator) is introduced as an intermediary component between the linear electrodes inside the insulating tube. This separator prevents direct contact between the electrodes, thereby eliminating the short circuit risk even if molten resin enters the insulating tube during the molding process.
Solution Approach 2:
The insulating member is preliminarily positioned between the linear electrodes before the molding process begins. By pre-establishing this insulation barrier, the system prevents potential short circuits that could occur during subsequent resin injection, addressing the problem before it can manifest.
2Adaptability or versatility
If the linear electrodes are provided spirally in the insulating tube, then the touch sensor unit can detect obstacles effectively, but the electrodes may come into contact with each other when the insulating tube is elastically deformed
Solution Approach 1:
The insulating member acts as a mediator that maintains separation between the spirally arranged linear electrodes. Even when external forces cause elastic deformation of the insulating tube and bring the electrodes closer, the insulating member prevents direct contact, ensuring reliable operation.
Solution Approach 2:
The insulating member provides beforehand cushioning by being positioned between the electrodes in advance. This preventive measure cushions against potential electrode contact that could occur during deformation, protecting the electrical functionality before any short circuit can happen.
3Object-affected harmful factors
If the tubular insulator is pressed from the outer side during resin supply, then resin flow into the insulating tube is prevented, but the pressing must be precisely controlled within the overlap range with the insertion protrusion
Solution Approach 1:
The insulating member with its insertion protrusion serves as a mediator that defines the precise pressing position. By pressing the tubular insulator within the overlap range where the insertion protrusion is located, the system creates a controlled barrier that prevents resin infiltration while maintaining manufacturing feasibility.
Solution Approach 2:
The insulating member's insertion protrusion structure provides self-alignment and self-positioning during the pressing operation. This self-service feature helps ensure that the pressing force is applied at the correct location without requiring extremely complex external positioning systems.
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 method effectively prevents short circuits between the electrodes, ensuring reliable operation of the touch sensor unit by maintaining the electrodes in a non-contact state within the tubular insulator, even when resin is injected during the molding process.
Implementation Method 1
a tubular insulator that is elastically deformed when an external force is applied, and the plurality of electrodes come into contact with each other as the tubular insulator is elastically deformed
Implementation Method 2
an insulating member including an insertion protrusion inserted into the tubular insulator from the end of the tubular insulator and interposed between the plurality of electrodes
Implementation Method 3
a second process of supplying molten resin into the mold in a state where the tubular insulator is pressed from an outer side of the sensor holder in the mold
Data Source
AI summary
The disclosure provides a manufacturing method of a touch sensor unit that includes a tubular insulator housing a plurality of electrodes, and the plurality of electrodes housed in the tubular insulator are prevented from being fixed in a short-circuited state by the resin flowing into the tubular insulator. The manufacturing method of the touch sensor unit includes: a first process of disposing an end of a sensor holder, a resistor, connection wires, and a separator, which are included in a mold part provided at an end of the touch sensor unit, in a mold; and a second process of supplying molten resin into the mold in a state where the tubular insulator housing linear electrodes is pressed from an outer side of the sensor holder in the mold. In the second process, the tubular insulator is pressed within a range where the tubular insulator and an insertion protrusion overlap.