Force Sensor Housing With Slidable Die And Bias Terminals
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Solution Overview
Problem
Existing force sensors lack efficient electrical connection mechanisms and retention methods, particularly in compact designs, which can lead to unreliable signal transmission and assembly complexities in applications requiring small mechanical footprints and low costs.
Innovation Solution
The force sensor design incorporates a housing with slidably received sense die and electrical terminals that provide a positive contact bias force against bond pads, along with a retention member that secures the sense die in place, facilitating improved electrical connections and assembly through over-molded lead frames and micro-molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sense die is inserted from the side with electrical terminals providing positive contact bias force, then electrical connection reliability is improved, but device complexity increases
Solution Approach 1:
The electrical terminals are integrated into the housing structure, merging the electrical connection function with the mechanical housing. The terminals are formed as part of the housing through over-molding or integration processes, eliminating separate terminal components and simplifying assembly while maintaining reliable electrical contact with the sense die bond pads.
Solution Approach 2:
The electrical terminals are pre-positioned and biased within the housing before the sense die is inserted. The positive contact bias force is already established in the terminal structure, so when the sense die is inserted, electrical contact is automatically made without requiring additional adjustment or complex alignment mechanisms.
2Reliability
If the sense die is slidably received with electrical terminals engaging bond pads, then electrical contact consistency is improved, but manufacturing complexity increases
Solution Approach 1:
The electrical terminals are designed with flexible or movable portions that can dynamically adjust during the insertion process. As the sense die is slidably inserted, the flexible terminal portions bend and conform to engage the bond pads, ensuring consistent electrical contact. This dynamic adaptation simplifies manufacturing by eliminating the need for precision alignment features.
Solution Approach 2:
The terminal structure incorporates material properties or geometric parameters that change during assembly. For example, the terminals may be made of elastomeric materials that deform under insertion force, or the terminal geometry may be designed to progressively engage the bond pads as the sense die moves into position, ensuring reliable contact without complex manufacturing steps.
3Reliability
If retention member is added to secure sense die, then assembly reliability is improved, but device complexity increases
Solution Approach 1:
The retention function is merged into the housing structure rather than being a separate component. The housing includes integrated retention features such as ribs, flanges, or interference-fit portions that secure the sense die in place during assembly and operation, eliminating the need for separate retention members while maintaining assembly reliability.
Solution Approach 2:
The sense die insertion and retention process is designed to be self-aligning and self-securing. The housing geometry and terminal structures are configured so that the sense die automatically finds its correct position and becomes retained through the insertion action itself, without requiring additional retention components or complex assembly steps.
Data Source
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AI summary
A force sensor or sensor assembly may include a sense die, a housing, and a force transmitting member. The sense die may include a force sensing region and at least one bond pad. The housing may include a sense die receiving cavity, at least one electrical terminal configured to engage a bond pad of the sense die, a retention member configured to prevent the sense die from sliding out of the housing, and a hole in the housing that exposes the force sensing region of the sense die to the force transmitting element. The housing may include one or more component parts. In some cases, the force sensor or sensor assembly may be configured on a microscale through micro-manufacturing techniques.