Flexible Electrical Connection for Sensor Assembly
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Solution Overview
Problem
Current sensor and control module connections are prone to mechanical damage during assembly and operation, and the assembly process is time-consuming and error-prone due to the use of rigid electrical connections, which can lead to incorrect installation and increased packaging complexity.
Innovation Solution
A flexible electrical connection using a combination of thin and thick plastic encapsulation sections along the electrical conductor allows for targeted deformation and installation adaptation, preventing mechanical damage and simplifying the assembly process by enabling precise positioning and reducing packaging volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid electrical connections are used for sensor connections, then mechanical strength and structural stability are improved, but the assembly process becomes time-consuming and error-prone due to incorrect installation and mechanical damage risks
Solution Approach 1:
The patent changes the physical state and mechanical properties of the electrical connection by introducing a flexible cable assembly with varying degrees of flexibility along its length. The cable transitions from a rigid structure to a controlled flexible structure, allowing it to adapt to different assembly positions and reduce installation errors while maintaining adequate mechanical strength through its constructed design.
Solution Approach 2:
The electrical connection is transformed from a static rigid structure to a dynamic flexible cable assembly that can adapt its shape and position during assembly and operation. This dynamic flexibility allows the cable to accommodate movement and positioning adjustments, enabling faster and more accurate assembly while maintaining structural integrity through its constructed design.
2Productivity
If flexible electrical connections are used without targeted deformation control, then assembly speed and adaptability are improved, but mechanical damage occurs due to twisting and improper handling
Solution Approach 1:
The patent applies local quality by creating different flexibility characteristics at different sections of the cable assembly. The cable has varying degrees of flexibility along its length, with more flexible sections allowing deformation and more rigid sections providing structural support. This localized differentiation enables the cable to deform in controlled ways during assembly while maintaining reliability in critical sections.
Solution Approach 2:
The electrical connection is segmented into multiple sections with different flexibility properties. This segmentation allows the cable to be divided into functional zones: sections that can deform to accommodate assembly variations and sections that maintain structural integrity. The segmented design prevents uncontrolled twisting while enabling necessary flexibility for correct installation.
3Loss of time
If permanently fixed sensors are used, then assembly time is reduced, but manufacturing precision requirements increase and additional test devices are required
Solution Approach 1:
The patent changes the mechanical parameter of the electrical connection from rigid to flexible, allowing the sensor assembly to accommodate positioning variations without requiring high manufacturing precision. The flexible cable absorbs dimensional tolerances and assembly variations, reducing the need for precision manufacturing and additional testing while maintaining reliable electrical connections.
Data Source
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Figure 3
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AI summary
A flexible electrical connection (28) for electrically contacting a sensor (10) or a sensor module (12) includes at least one electrical conductor (14) extending in an axial length between a moveable component (18) and a stationary component (20). The at least one electrical conductor (14) is fixed to a sensor housing (22) via a rigid coupling (46) and is connected to a housing (16) of the sensor (10) or sensor module (12) via a movable, rotatable coupling (54). The at least one electrical conductor (14) includes first sections (32) and second sections (34), the second sections (34) including an injected coating. The first sections (32) have a higher deformation property than the second sections (34), and the first sections (32) do not include an injected coating, or they include an injected coating having the thickness of a film hinge. The first and second sections extend along an axial length of the at least one electrical conductor (14), The first sections (32) have a thickness (36) that is less than the thickness (38) of the second sections (34). The first and second sections define a hinge of the electrical conductor (14) by their lengths, such that in a bent position (42), a bend (48) of the at least one electrical conductor (14) of at least 90° is formed within one of said first sections (32).