Articulated Proximity Sensor Housing With Bendable PCB
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Solution Overview
Problem
Conventional proximity sensors have limited flexibility and rigidity along their length, making them inflexible for positioning in tight spaces and prone to damage during external movements, which compromises detection reliability and increases the risk of damage, especially in applications like robotics where continuous movement and external forces are involved.
Innovation Solution
The sensor housing is designed with multiple segments linked via pivot axes, allowing bending and increased flexibility, while the circuit board is also made bendable to accommodate these movements, with a protective layer to safeguard the detection circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is made rigid along its length direction to ensure stable positioning, then measurement precision is improved, but adaptability to different positions and resistance to external forces deteriorates
Solution Approach 1:
The housing is divided into multiple segments (front segment, middle segment, rear segment) that can rotate relative to each other around pivot axes. This segmentation allows the sensor to adapt its shape and positioning while maintaining measurement accuracy through the stable front segment that holds the sensing element.
Solution Approach 2:
The sensor housing transitions from a rigid static structure to a dynamic articulated structure with rotational degrees of freedom. The pivot axes enable controlled movement and adaptation to different positions, while the sensing element remains stabilized for accurate measurements.
2Adaptability or versatility
If the sensor housing is made flexible to allow bending and positioning in tight spaces, then adaptability is improved, but structural strength and protection of internal components deteriorates
Solution Approach 1:
The housing is segmented into rigid sections connected by pivot axes, creating flexibility through articulation rather than material flexibility. Each segment maintains structural strength while the overall structure gains adaptability through controlled rotation at the joints.
Solution Approach 2:
A protective layer (such as a flexible membrane or coating) is applied to the housing segments to protect internal components during bending and movement, maintaining structural integrity while allowing articulation.
3Reliability
If the circuit board is made rigid to ensure stable electrical connections, then reliability is improved, but flexibility to accommodate housing bending deteriorates
Solution Approach 1:
The circuit board transitions from a rigid static structure to a flexible dynamic structure that can bend with the housing segments. This flexibility maintains electrical connections during articulation while reliability is ensured through proper flexible circuit design and connection points.
Solution Approach 2:
A flexible protective layer or coating is applied to the circuit board, allowing it to bend with the housing segments while maintaining electrical connections and protecting against damage during articulation.
4Ease of manufacture
If the sensor is made long to accommodate detection circuitry behind the sensing element, then device functionality is improved, but ease of operation in limited spaces deteriorates
Solution Approach 1:
The long sensor housing is divided into segments that can be articulated and folded into compact configurations. This allows the full-length housing needed for circuitry accommodation to be operated in limited spaces by bending the segments around pivot axes.
Data Source
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Figure 3~5
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AI summary
The invention relates to a proximity sensor for detecting the proximity of an object, the sensor comprising a sensing element (11), a detection circuitry (65), and a housing (5), the sensing element (11) being arranged in a front portion (21) of the housing (5) such that it is adapted to interact with the object through the front portion (21) and the detection circuitry being interconnected with the sensing element (11) in order to receive a detection signal from the sensing element (11), wherein the detection circuitry (65) is provided on a circuit board (15, 15A, 15B, 15C) extending at least through a middle portion (22) of the housing (5). To allow a better flexibility of the sensor along its length expansion, the invention proposes that the housing (5) comprises multiple segments (41, 42, 43, 44) that are consecutively arranged in a longitudinal direction (27) from a rear end (56) toward a front end (55) of the housing (5), wherein neighboring segments of said segments (41, 42, 43, 44) are linked to each other via a respective pivot axis (35, 39, 40) extending transversely with respect to said longitudinal direction (27), such that the housing (5) is bendable around each of said pivot axes (35, 39, 40), wherein both of said front portion (21) and said middle portion (22) each comprises at least one of said segments (41, 42, 43, 44), and wherein the circuit board (15, 15A, 15B, 15C) comprises at least one bendable section (61, 75, 76, 77, 85, 86) extending transversely with respect to said longitudinal direction (27), said bendable section (61, 75, 76, 77, 85, 86) being provided inside said neighboring segments (41, 42, 43, 44).