Magnetic Sensor Lead Frame Alignment and Recess Design
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Solution Overview
Problem
Existing methods for positioning electronic devices, such as magnetic sensors, lack precision in two-dimensional or three-dimensional space and do not adequately address the need for accurate z-axis location, especially in systems without printed circuit boards.
Innovation Solution
A sensor component with a housing and lead frame, featuring recesses on opposite sides for heat-stacking and alignment, and elongated leads with alignment holes and tabs for precise positioning and testing, allowing for compact and secure mounting without additional material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional positioning methods (guide pins, sockets) are used, then electrical connections are provided, but positioning precision in two-dimensional and three-dimensional space is insufficient
Solution Approach 1:
The patent integrates alignment features directly into the lead frame structure. Alignment tabs extend from the lead frame body, and alignment holes are formed in the leads themselves, nesting the positioning function within the existing electrical connection structure rather than adding separate positioning components.
Solution Approach 2:
The lead frame serves dual functions: providing electrical connections through its leads and providing positioning precision through integrated alignment tabs and holes. This multi-functional design eliminates the need for separate positioning structures, resolving the contradiction between positioning precision and device complexity.
2Ease of operation
If surface-mount packages are used to simplify assembly, then connection pins are eliminated, but positioning accuracy and z-axis location control are lost
Solution Approach 1:
The alignment tabs and holes are nested within the lead frame structure itself. The tabs extend from the lead frame body and the holes are formed in the leads, integrating the positioning function into the existing surface-mount package structure without adding external positioning components.
Solution Approach 2:
Specific portions of the lead frame are given different properties: the leads provide electrical connection functionality while the alignment tabs and holes provide positioning functionality. This local differentiation allows the package to maintain simplicity while achieving precise positioning.
3Manufacturing precision
If alignment features are added to improve positioning, then positioning precision increases, but the component size and complexity increase
Solution Approach 1:
The alignment features are nested within the existing lead frame geometry. The alignment tabs extend from the lead frame body and the alignment holes are formed in the leads themselves, utilizing the existing structural space rather than adding external alignment components that would increase overall package volume.
Solution Approach 2:
The lead frame structure serves multiple functions simultaneously: electrical connection through the leads and positioning through the integrated alignment tabs and holes. This eliminates the need for separate alignment components that would increase component size.
4Ease of repair
If testing provisions are added to the component, then testability improves, but compactness and standard dimensions are compromised
Solution Approach 1:
The test access provisions are nested within the existing lead frame structure. Test holes are formed in the leads and test tabs extend from the lead frame, utilizing the existing structural elements for dual purposes of electrical connection and testing access.
Solution Approach 2:
The leads and lead frame structure serve multiple functions: electrical connection, positioning through alignment features, and testing through integrated holes and tabs. This multi-functionality improves testability without compromising compactness or requiring non-standard dimensions.
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 provides accurate and secure positioning in three dimensions, reduces the risk of movement or corrosion, and enables improved testability while maintaining standard dimensions and tool compatibility, resulting in a compact and reliable electronic component assembly.
Implementation Method 1
The housing comprises two (and preferably only two) recesses arranged on two opposite sides of the housing for allowing the component to be mounted by heat-stacking
Data Source
AI summary
A sensor comprises a housing; and a lead frame comprising at least three elongated leads having an exterior portion extending from the housing; and a magnetic sensor circuit disposed in the housing, and connected to the lead frame. The housing comprises two recesses arranged on two opposite sides of the housing for allowing the sensor to be mounted to a support. The lead frame may further comprise a plurality of tabs disposed between the elongated leads, for use as test pins. A component assembly comprising said sensor mounted on a support between deformable protrusions. A method of making said component assembly, comprising the step of positioning said component on the support between said protrusions, and deforming said protrusions such that they are at least partially disposed within the recesses.