Actuator Coil Substrate Positioning via Conductive Bonding
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Solution Overview
Problem
Existing actuators with a coil and magnet structure face issues due to deviations in the mounting position of the coil relative to the magnetic sensor, leading to variations in actuator characteristics.
Innovation Solution
The actuator design includes a coil substrate with a magnetic sensor mounted on a base material connected to a base substrate through conductive bonding, reducing positional deviations and incorporating a shield conductor to minimize noise interference, with a flexible connection for improved stability and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil substrate is mounted on the base substrate separately, then the manufacturing process is flexible, but the positional relationship between the coil and magnetic sensor deviates
Solution Approach 1:
The magnetic sensor is integrated directly onto the coil substrate, merging two previously separate components. This ensures their positional relationship is fixed at the substrate level, eliminating mounting deviation while preserving manufacturing flexibility through the integrated substrate design
2Ease of manufacture
If the magnetic sensor and coil substrate are each mounted on the base substrate, then the assembly is modular, but the positional relationship between coil and magnetic sensor deviates
Solution Approach 1:
The magnetic sensor and coil substrate are merged into a single integrated unit, eliminating the intermediate mounting step on the base substrate. This reduces the number of mounting interfaces and cumulative positioning errors, ensuring consistent actuator characteristics across production batches
3Device complexity
If the coil substrate is mounted on the base substrate, then the structure is simple, but noise interference affects the magnetic sensor
Solution Approach 1:
A shield conductor is introduced as an intermediary element between the coil substrate and the magnetic sensor. This shield conductor blocks electromagnetic noise from the coil while allowing the magnetic field from the magnet to reach the sensor, protecting the sensor without adding complex structural elements
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 effectively reduces variations in actuator characteristics by maintaining precise positional relationships between the coil and magnetic sensor, enhances magnetic field detection accuracy, and increases yield rates by allowing separate lamination of coil and base substrates with high positional accuracy.
Implementation Method 1
the coil substrate is connected to the base substrate through a conductive bonding material
Implementation Method 2
a magnet which receives a magnetic field generated by the coil
Implementation Method 3
a magnetic sensor mounted on the base material
Data Source
AI summary
An actuator includes a coil substrate including a coil, a base substrate including a coil drive circuit, and a magnet to receive a magnetic field generated by the coil. A magnetic sensor is mounted on the coil substrate. The coil substrate on which the magnetic sensor is mounted is connected to the base substrate through a conductive bonding material.