Label Sensor PCB Design for Reliable Elastic Contact
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Solution Overview
Problem
Existing label sensors for labeling machines require multiple components made of different materials, leading to design and cost challenges, as well as issues with material attachment and electrical connections.
Innovation Solution
A label sensor designed as a single, integrated printed circuit board with an insulating carrier layer and conductor levels, eliminating the need for discrete components like spring elements and fastening parts, and utilizing the board's elasticity and electrical connection options for reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple discrete components (spring elements, fastening parts) are used to construct the sensor body, then the sensor can achieve elastic contact and electrical connection, but the device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent combines multiple discrete components (spring elements, fastening parts, electrical contacts) into a single integrated sensor body made of elastic material. This merging eliminates the need for separate components while maintaining the elastic contact function and electrical connection capabilities, thereby reducing device complexity without sacrificing reliability
Solution Approach 2:
The elastic sensor body material simultaneously provides multiple functions: mechanical elasticity for contact, electrical conductivity for signal transmission, and structural integrity for mounting. This multi-functionality replaces several specialized components with a single universal element, simplifying the overall device structure
2Reliability
If multiple discrete components are assembled together, then the sensor can achieve functional requirements, but the manufacturing cost and design effort increase
Solution Approach 1:
The patent integrates electrical contacts and mechanical mounting features directly into the elastic sensor body material through processes like embedding or co-forming. This eliminates separate assembly steps for attaching spring elements and fastening parts, significantly simplifying manufacturing while ensuring reliable electrical connections through the integrated structure
3Adaptability or versatility
If discrete components are used in the sensor body, then specific functions can be assigned to each component, but the attachment integrity and electrical connection reliability deteriorate
Solution Approach 1:
The patent combines multiple specialized components into a single elastic sensor body that inherently provides all necessary functions. The elastic material itself is configured with integrated electrical contacts and mounting features, eliminating attachment interfaces between separate components and ensuring reliable electrical connections through the unified structure
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 simplifies manufacturing, reduces costs, and provides reliable and diverse electrical connection options, enhancing the sensor's flexibility and longevity while maintaining efficient label detection.
Implementation Method 1
The sensor head is equipped with an electromagnet, which has a ferromagnetic core and a coil
Implementation Method 2
This changed distance causes a change in the magnetic field between the electromagnet formed with the sensor coil and the opposite ferromagnetic part and is thus expressed in a changed electrical signal at the coil of the sensor head
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to a label sensor (1) for scanning labels on a carrier tape, comprising a sensor body (2), a ferromagnetic core (18), a coil (19) and a scanning element (17), wherein the sensor body is designed as a printed circuit board having at least one electrically insulating carrier layer (26, 30, 35) and at least one conductor plane (27, 36) arranged on the carrier layer with electrical conductors, and wherein a central connection area (4) of the sensor body (2) has a lesser thickness or attenuation (14) compared to the contact and sensor areas (3, 5) adjoining on both sides.