Dual Magnetic Sensor Terminal Layout for Interference-Free Welding
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Solution Overview
Problem
The existing magnetic detection devices with two magnetic sensors face challenges in welding terminals and wiring lines due to the protrusion of terminals in the same direction, leading to interference during the resistance welding process, which complicates the manufacturing process and reduces efficiency.
Innovation Solution
The magnetic detection device design includes a configuration where the terminals and wiring lines are arranged in a specific pattern, with overlapping portions positioned to avoid interference, allowing for easy welding by using resistance welding in a uniaxial direction, and incorporating a resin body with integrated wiring lines and terminals that are parallel to each other, ensuring clear paths for welding electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two magnetic sensors are combined with a resin body and terminals protrude in the same direction, then the device structure is simplified, but the welding electrode interferes with the other terminal during resistance welding
Solution Approach 1:
The patent applies asymmetry by making the first terminals and second terminals protrude in opposite directions from the resin body. This asymmetric arrangement ensures that when welding electrodes are applied to connect terminals to wiring lines, the welding process for one terminal does not interfere with the other terminal, thus resolving the manufacturing difficulty while maintaining structural simplicity
Solution Approach 2:
The patent resolves the welding interference problem by changing the spatial arrangement from a planar configuration to a three-dimensional configuration where terminals extend in opposite directions. This dimensional change allows welding electrodes to access terminals without interfering with adjacent terminals, enabling successful resistance welding while maintaining a compact device structure
2Device complexity
If terminals are arranged side by side in the same direction, then the wiring layout is simplified, but the welding electrode cannot access the terminal without interfering with other terminals
Solution Approach 1:
The patent applies asymmetry by arranging the first terminals and second terminals to protrude in opposite directions from the resin body. This asymmetric terminal arrangement ensures that welding electrodes can access each terminal without interfering with the other terminal, thus resolving the welding operation difficulty while maintaining simplified wiring layout
Solution Approach 2:
The resin body acts as an intermediary element that positions the terminals in opposite directions. This intermediary structure enables the terminals to be arranged in a configuration that facilitates welding access while maintaining the simplified wiring layout, effectively mediating between the conflicting requirements
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 configuration enables easy and efficient welding of terminals and wiring lines, reducing manufacturing complexity and increasing the reliability of the magnetic detection device, while also allowing for the use of common components to reduce production costs.
Implementation Method 1
a current is caused to flow between the pair of welding electrodes while pressure is applied to the terminal and the wiring line by the pair of welding electrodes. In this manner, a contact part between the terminal and the wiring line is melted by Joule heat so that the terminal and the wiring line are welded to each other
Data Source
AI summary
A magnetic detection device includes a first magnetic sensor, a second magnetic sensor, and a resin body. The first magnetic sensor includes a first sealing body and first terminals. The second magnetic sensor includes a second sealing body and second terminals. The resin body includes a resin-body main body, first wiring lines, and second wiring lines. Each of the first wiring lines includes a first overlapping portion overlapping with corresponding one of the first terminals. As viewed in a normal direction of each of the first terminals, the first overlapping portion is arranged at a position shifted from all of the second terminals and the second wiring lines. Each of the first wiring lines is welded to corresponding one of the first terminals at the first overlapping portion.