Biased Sensor Contact Assembly for Stable Dry Connections
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Solution Overview
Problem
Existing electronic devices, such as power semiconductor modules, face challenges in efficiently and compactly integrating temperature sensors, particularly in designs where minimal modification is required and soldering or other joining methods are avoided.
Innovation Solution
The electronic device incorporates a sensor element for measuring physical quantities, such as temperature, and a mechanically biased contact element that forms a dry connection with the sensor element and the measurement surface, ensuring reliable and secure attachment without the need for soldering or other material-locking methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a sensor element is integrated into an electronic device without pre-designed sensor integration, then the adaptability of the device is improved, but the device complexity increases due to additional components and assembly steps
Solution Approach 1:
The contact element is designed to be self-biasing through its own elastic deformation, automatically pressing the sensor element against the measurement surface without requiring external actuation or complex mounting mechanisms. The contact element's elasticity provides self-regulating contact pressure that maintains reliable electrical and mechanical connection.
Solution Approach 2:
The contact element serves multiple functions simultaneously: it provides electrical connection to the sensor element, applies mechanical biasing force, and maintains contact pressure during device operation. This multi-functionality reduces the need for separate components and simplifies the overall structure.
2Ease of manufacture
If dry connections are used to connect the sensor element, then the ease of manufacture is improved by avoiding soldering or gluing, but the reliability of the connection may worsen due to potential loosening
Solution Approach 1:
The contact element transitions from a static connection to a dynamic, self-adjusting connection. The elastic contact element continuously adapts to thermal expansion, mechanical stress, and assembly variations, maintaining optimal contact pressure throughout the device lifecycle without requiring permanent bonding.
Solution Approach 2:
The elastic contact element is pre-biased to provide continuous contact pressure that compensates for future thermal expansion, mechanical settling, or vibration-induced loosening. This beforehand cushioning ensures the connection remains reliable under various operating conditions without requiring permanent fixation.
3Measurement precision
If a mechanically biased contact element is used to press the sensor element, then the measurement precision is improved by ensuring stable contact, but the device complexity increases due to the elastic component
Solution Approach 1:
The electrical connection function and the mechanical biasing function are merged into a single contact element. This integration eliminates the need for separate springs, clamps, or adjustment mechanisms, reducing component count while maintaining stable contact pressure for precise measurements.
Solution Approach 2:
The contact element generates its own biasing force through elastic deformation, eliminating the need for external actuators, adjustment mechanisms, or additional biasing components. The element's geometry and material properties provide the necessary mechanical force automatically.
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 solution enhances the accuracy of physical quantity measurement during device operation, allows for easy integration of sensors in devices without pre-designed sensor integration, and maintains a compact design by avoiding the use of soldering or other joining methods.
Implementation Method 1
The contact element is configured to be mechanically biased. The contact element is mechanically biased in order to prevent loosening of the at least one dry connection
Data Source
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AI summary
According to an embodiment, the electronic device (100) comprises a sensor element (1) for measuring a physical quantity in the electronic device and a contact element (2) which is configured to be mechanically biased. Furthermore, the electronic device comprises a measurement surface (30, 60, 90) at which the physical quantity is to be measured with the help of the sensor element. The sensor element is placed on the measurement surface. The contact element is electrically connected to the sensor element. At least one of the connection between the sensor element and the contact element and the connection between the sensor element and the measurement surface is a dry connection. The contact element is mechanically biased in order to prevent loosening of the at least one dry connection.