Direct-Solder Sensor Assembly Without PCB Wiring
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Solution Overview
Problem
The high cost of manufacturing electronic sensor assemblies in motor vehicles is attributed to the use of printed circuits and numerous soldering operations, which are necessary for connecting flexible electrical conductors and electronic sensor members.
Innovation Solution
The sensor assembly eliminates the need for a printed circuit by directly soldering connection pins of the electronic sensor member to stripped parts of flexible conductors, using a surface mount technology, and incorporates immobilization means in a plastic body to secure the conductors in three perpendicular directions, ensuring stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If printed circuits are used to connect electronic sensor members, then electrical connection is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent extracts and removes the printed circuit board from the sensor assembly, replacing it with direct wire connections between conductors and sensor pins. This eliminates the complex PCB structure while maintaining electrical connectivity, thereby reducing both manufacturing cost and device complexity.
Solution Approach 2:
The patent segments the electrical connection system into individual wire connections rather than a continuous printed circuit pattern. Each conductor is independently routed and connected to specific sensor pins, allowing for simpler manufacturing and reduced overall complexity.
2Productivity
If multiple soldering operations are performed to connect flexible conductors to printed circuit and sensor members, then electrical connection is established, but manufacturing time increases and productivity decreases
Solution Approach 1:
By removing the printed circuit board intermediate connection layer, the patent reduces the number of soldering operations from multiple steps (conductors to PCB, PCB to sensors) to a single direct soldering step (conductors to sensor pins), thereby improving productivity and reducing manufacturing time.
3Reliability
If flexible conductors are not immobilized in the body, then assembly is simpler, but reliability decreases due to risk of accidental separation
Solution Approach 1:
The patent merges the conductor immobilization function with the sensor housing structure. The housing incorporates integrated features such as channels, grooves, or mounting structures that simultaneously provide mechanical support and secure the flexible conductors in place, eliminating the need for separate immobilization components while maintaining connection reliability.
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 approach reduces manufacturing costs and minimizes the risk of conductor separation while allowing for efficient assembly using surface mount soldering, thereby simplifying the structure and enhancing reliability.
Implementation Method 1
two electrical connection conductors for connecting this electronic sensor member that are soldered to two corresponding connection pins of this electronic sensor member
Implementation Method 2
a flexible conductor provided with a conductive core and an insulating sheath, the sheath being interrupted to separate a so-called coated part of the conductor
Implementation Method 3
the two connection pins of the electronic member being soldered directly to the two corresponding stripped parts of the flexible conductors
Data Source
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AI summary
The invention concerns a sensor assembly (10) comprising at least an electronic sensor member (16,18), two flexible electrical connection conductors (14) that are soldered to two corresponding connection pins (16P, 18P) of this electronic sensor member (16, 18). The two connection pins (16P, 18P) are soldered directly to the two corresponding stripped parts (14A) of the flexible conductors (14). The assembly comprises a body (12) housing the flexible conductors (14) and the electronic sensor member (16, 18). The body (12) comprises means (34, 48) for immobilising the flexible conductors in three directions perpendicular to each other. The immobilisation means (34, 48) are distributed in first (12A) and second (12B) parts of the body (12) that can be separated from each other between a configuration set up for mounting the flexible conductors (14) and the electronic sensor member (16, 18) in the body (12) and a configuration in which the sensor assembly (10) is ready for being used.