Windshield Sensor Flex Connection for Shock-Resistant Assembly
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Solution Overview
Problem
Existing windshield sensing devices for motor vehicles face challenges in achieving a simple and cost-effective assembly process due to complex configurations and multiple parts, which complicate the secure attachment of temperature and humidity sensors to withstand mechanical shock and vibrations.
Innovation Solution
A sensing device design featuring a flexible curved interconnecting means with soldered and mechanical connections, pre-fabricated with a printed circuit board, allowing for a simplified assembly process through form-fit connections and elastic restoring forces to ensure secure attachment to the windshield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a complex assembly of sensor unit comprising temperature and humidity module is used to reduce sensor influence on measurements, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the temperature sensor, humidity sensor, and their supporting structures into a single integrated sensor unit that is mounted on the windshield. This merging approach maintains the functional separation needed for accurate measurements while simplifying the overall device assembly and reducing the number of discrete components.
Solution Approach 2:
The patent positions the sensor unit at a specific distance from the windshield surface, creating a spatial separation that reduces the influence of the sensor housing and mounting structures on the measurements. This dimensional arrangement allows the sensors to operate with minimal interference while maintaining a compact overall design.
2Reliability
If multiple different parts are used in sensor device assembly, then reliability of sensor attachment is improved, but assembly time increases
Solution Approach 1:
The patent employs a pre-fabricated sensor unit that integrates the temperature sensor, humidity sensor, and mounting structure into a single ready-to-install component. This preliminary assembly of critical parts before final installation reduces on-site assembly time while maintaining the reliability benefits of using multiple specialized components.
Solution Approach 2:
The patent divides the sensing device into modular segments: a sensor unit containing the temperature and humidity sensors, a mounting structure with adhesive layer, and a housing. This segmentation allows each component to be optimized independently while simplifying the final assembly process through modular integration.
3Reliability
If sensor is kept in constant contact with windshield surface to withstand mechanical shock and vibration, then reliability is improved, but ease of manufacture worsens due to secure attachment requirements
Solution Approach 1:
The patent replaces complex mechanical attachment systems with a chemical bonding approach using an adhesive layer between 0.1mm and 1mm thick. This adhesive bond provides sufficient mechanical strength to withstand vehicle vibrations and shocks while simplifying the manufacturing and installation process compared to traditional mechanical fastening methods.
Solution Approach 2:
The patent optimizes the adhesive layer thickness parameter to a specific range (0.1mm to 1mm) that balances multiple requirements: providing sufficient bonding strength for reliable attachment, allowing for manufacturing tolerances, and maintaining sensor contact with the windshield surface under various vibration and shock conditions.
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 a reliable, efficient, and cost-effective assembly of the sensing device, ensuring consistent contact with the windshield and reducing the complexity of the assembly process while maintaining precise temperature and humidity monitoring.
Implementation Method 1
pushed by a spring or by means of the elastic restoring force of the flex circuit board against the vehicle window
Implementation Method 2
The flexible curved portion of the interconnecting means can be made with a combination of soldered and mechanical connections with the housing
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
The invention relates to a sensing device for a windshield comprising a housing (102, 402) comprising a printed circuit board (104), at least one sensor (106) and an interconnecting means (108, 308, 358) electrically connecting the at least one sensor (106) to the printed circuit board (104), wherein the interconnecting means (108, 308, 358) has the form of a flexible curved portion (112, 412c) and is connected to the printed circuit board (104) by a first end portion (108a, 308a, 358a), characterised in that a second end portion (108b, 308b, 358b) of the interconnecting means (108, 308, 358) realises a form-fit and/or force-fit connection with a wall of the housing (102, 402) in at least one direction.