Circuit Carrier Force-Free Sensor Connection
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Solution Overview
Problem
Existing sensor unit connection systems apply forces to pressure measuring cells during assembly, potentially influencing measurement results and increasing the risk of contact failures due to multiple contact junctions.
Innovation Solution
A circuit carrier that combines the functionality of a contact piece and a circuit board carrier, allowing force-free connection to the measuring cell and enabling versatile positioning of the circuit board, with a modular structure that includes a protective sleeve and support unit for integrated contact protection and reduced contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection units use multiple contact junctions to connect the measuring cell to the circuit board, then the electrical connection can be established, but the risk of contact failures increases and measurement precision deteriorates due to force effects on the measuring cell
Solution Approach 1:
The circuit carrier integrates multiple functions into a single component: it serves as both the contact piece for electrical connection and the carrier for the circuit board. This merging eliminates the need for separate contact junctions and reduces the number of connection points, thereby decreasing the risk of contact failures while avoiding force effects on the measuring cell that would compromise measurement precision.
Solution Approach 2:
The invention extracts and eliminates unnecessary intermediate contact junctions from the connection path. By making the circuit carrier itself the direct contact piece that touches the measuring cell, the design removes the harmful intermediate steps that would increase contact failure risk and apply unwanted forces to the measuring cell.
2Device complexity
If the circuit board is rigidly fixed in position, then the assembly structure is simplified, but the adaptability to different installation spaces and configurations is reduced
Solution Approach 1:
The circuit carrier provides dynamic positioning capabilities for the circuit board through its geometric features. The recess with angled surfaces allows the circuit board to be positioned at different angles and orientations while maintaining a simple overall assembly structure. This dynamic adaptability enables the same basic structure to accommodate various installation spaces and configurations without increasing complexity.
Solution Approach 2:
The invention adds positional and angular degrees of freedom to the circuit board mounting by utilizing three-dimensional geometric features in the circuit carrier. The recess with multiple angled surfaces enables positioning in different spatial dimensions and orientations, providing versatility for various installation scenarios while keeping the assembly structure relatively simple.
3Volume of moving object
If the circuit carrier is placed close to the measuring cell, then the installation space is minimized, but the measuring cell is subjected to force effects during assembly that may influence measurement results
Solution Approach 1:
The circuit carrier acts as an intermediary component that mediates between the measuring cell and the circuit board. By designing the circuit carrier with a recess that accommodates the measuring cell without direct contact, and using compliant elements like conductive adhesive domes, the intermediary structure minimizes force transmission to the measuring cell while still enabling close integration for compact installation space.
Solution Approach 2:
The circuit carrier design incorporates cushioning elements beforehand to protect the measuring cell from assembly forces. The recess geometry and compliant contact surfaces are designed in advance to absorb and distribute assembly forces, preventing them from being transmitted to the measuring cell and influencing measurement results, while still allowing compact overall dimensions.
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 reduces the risk of measurement interference, enhances reliability by minimizing contact failures, and allows for compact and versatile sensor unit design with improved installation space optimization and modular functionality.
Implementation Method 1
The circuit board can be mechanically and electrically connected to the circuit carrier directly at the second interface by means of conductive adhesive bonding
Implementation Method 2
the conductor tracks and the conductive adhesive domes are produced in a galvanic process as a metallic surface coating on the galvanized plastic
Data Source
AI summary
A circuit carrier for a sensor unit comprises a first interface via which at least one electrical output signal is tapped at least at one connection point of a measuring cell, a second interface via which the at least one electrical output signal of the measuring cell is applied via at least one first contact element to a circuit board with an electronic circuit, and a hollow, cylindrical main body. The main body includes an inner joining geometry defined on an inner contour which defines at least in part the first interface, an outer joining geometry which defines at least in part the second interface, and configured to electrically connect to a connection point of the measuring cell in a force-free manner. The outer joining geometry is configured as a receiving pocket with a protruding collar, and includes the at least one first contact element.