Magnetic Sensor Unit Asymmetric Terminal Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor units with Hall ICs mounted on both sides of a circuit board require a reflow process twice, increasing the risk of pin-to-pin short circuits between adjacent ICs, particularly when small outline package ICs are placed adjacent to each other.
Innovation Solution
A sensor unit design where magnetic sensors are mounted on a common surface of a circuit board with asymmetrically placed primary and secondary terminal groups, allowing for a single reflow process and minimizing the risk of short circuits by orienting adjacent sensors in the same direction with their terminal groups positioned asymmetrically relative to the center line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Hall ICs are mounted on both front and rear surfaces of the circuit board, then the sensor unit can achieve proper electrical connections and functionality, but the reflow process needs to be performed twice increasing manufacturing complexity and risk of pin-to-pin short circuits
Solution Approach 1:
The patent transitions from a three-dimensional arrangement (mounting ICs on both front and rear surfaces of the circuit board) to a two-dimensional arrangement (mounting all ICs on the front surface only). This dimensional change eliminates the need for dual reflow processes while maintaining proper electrical connections through redesigned terminal group arrangements and signal routing on the circuit board.
Solution Approach 2:
The patent employs asymmetric arrangement of terminal groups on the ICs, where primary terminal groups and secondary terminal groups are positioned at different locations. This asymmetric design, combined with specific orientation requirements for adjacent ICs, enables all ICs to be mounted on the same surface with proper signal routing, avoiding the need for back-side mounting and dual reflow processes.
2Area of stationary object
If small outline package ICs are placed adjacent to each other on a common surface, then the circuit board area is utilized efficiently, but there is a possibility of pin-to-pin short circuit between the ICs
Solution Approach 1:
The patent specifies that adjacent ICs shall be oriented in the same direction with their primary terminal groups positioned on the same side. This asymmetric orientation strategy creates a systematic terminal arrangement that facilitates proper signal routing and reduces the likelihood of pin-to-pin short circuits while maintaining efficient space utilization on the circuit board.
Solution Approach 2:
The patent applies different orientation requirements to different groups of ICs based on their functional roles. Magnetic sensors, for example, are required to have their primary terminal groups on the same side when arranged adjacently, while other ICs may have different orientation requirements. This localized quality approach optimizes both space utilization and short circuit prevention for each functional group.
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 design enables reliable mounting of magnetic sensors on a common surface with reduced risk of short circuits and simplifies the manufacturing process by eliminating the need for dual reflow processes, enhancing the reliability and efficiency of sensor unit assembly.
Implementation Method 1
Each of the plurality of magnetic sensors includes a magnetic sensing element... The magnetic sensing element senses a magnetic field
Implementation Method 2
The encapsulating portion encapsulates the magnetic sensing element
Implementation Method 3
The shield member shields magnetism applied from an outside
Data Source
AI summary
A magnetic sensor of a sensor unit includes magnetic sensing elements, an encapsulating portion, a primary terminal group and a secondary terminal group. Another magnetic sensor includes magnetic sensing elements, an encapsulating portion, a primary terminal group and a secondary terminal group. The magnetic sensors are mounted on a common surface of a circuit board. The adjacent two magnetic sensors, which are oriented in a common direction, are arranged such that the secondary terminal group of one of the adjacent two magnetic sensors is opposed to the primary terminal group of the other one of the adjacent two magnetic sensors. A primary output terminal and a secondary output terminal are placed asymmetrically to each other with respect to a center line of the encapsulating portion.