Aircraft Surface Sensor Mounting with Flexible Circuit
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Solution Overview
Problem
Existing measuring devices for aircraft surfaces are complex, difficult to assemble, and prone to electrical interconnection issues, making them challenging to maintain and repair.
Innovation Solution
A measuring device with open housings for sensors and a flexible printed circuit, covered by a film that provides insulation and an aerodynamic profile, allowing for easy assembly and maintenance, using a support with positioning marks for precise alignment and attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple housings and covers are used to protect sensors and electrical connections, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple separate housings and covers into a single integrated support structure. The support contains cavities that house sensors and electrical connections while providing protection, eliminating the need for multiple separate protective components. This reduces assembly complexity while maintaining the protective function.
Solution Approach 2:
The support structure serves multiple functions simultaneously: it provides mechanical support, contains cavities for sensor housing, provides electrical insulation, and offers aerodynamic profiling. This multi-functionality replaces what would otherwise require multiple separate components.
2Reliability
If complex interconnection systems with soldering and shielding are used, then reliability is improved, but ease of repair worsens
Solution Approach 1:
The patent segments the electrical interconnection system into modular components. The flexible printed circuit board is divided into separate connection elements that can be independently accessed and replaced. This segmentation allows for easier repair without requiring complex disassembly of the entire device.
Solution Approach 2:
The patent introduces a flexible printed circuit board as an intermediary element between the sensors and the external connection system. This flexible circuit board provides electrical connections that are easier to access and replace compared to traditional rigid soldered connections, while maintaining reliable electrical interconnection.
3Manufacturing precision
If traditional manufacturing processes with multiple assembly steps are used, then manufacturing precision is improved, but productivity worsens
Solution Approach 1:
The patent incorporates preliminary action by pre-positioning sensors and electrical connections within the support structure during manufacturing. The support is designed with pre-formed cavities and integrated circuit board mounting features that enable precise alignment without requiring complex assembly steps. Positioning marks are pre-provided to facilitate accurate placement.
Solution Approach 2:
The patent combines multiple assembly operations into a single integrated support structure. Sensors, electrical connections, and protective elements are merged into one component that can be manufactured and assembled as a single unit, reducing the number of assembly steps while maintaining manufacturing precision through integrated design features.
4Measurement precision
If a streamlined profile is used to minimize aerodynamic disturbance, then measurement accuracy is improved, but ease of manufacture worsens
Solution Approach 1:
The patent uses a thin film covering the sensors and support structure to create a streamlined aerodynamic profile. This thin film approach allows for an aerodynamically optimized shape while remaining simple to manufacture, as the film can be applied as a thin coating or covering rather than requiring complex molded structures.
Data Source
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Figure 5~6
AI summary
The present invention relates to a measurement device which can be attached to an outer wall of a movable object or of a stationary object arranged in a flow of air in order to measure physical quantities. The measurement device comprises a mounting (5) which has recesses (11) having an opening leading to the outside, sensors (6) being provided in said recesses. The device includes a cavity (8) into which the recesses (11) lead and which contains a flexible printed circuit (10), to which the sensors (6) are connected. The method for manufacturing such a device is simplified in the invention by including the following steps: attaching sensors (6) to the flexible printed circuit (10); and attaching the flexible printed circuit (10) provided with sensors (6) to the mounting (5), the sensors (6) being inserted into the recesses (11) and the circuit (10) being inserted into the cavity (8).