Modular Electrical Connector Interface for Fast Sensor Assembly
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Solution Overview
Problem
Existing methods for assembling inductive proximity sensors require manual soldering and are not cost-efficient, especially when integrating peripheral contact elements like plug connectors or cables, which can be space-consuming and prone to damage.
Innovation Solution
An electrical connector kit with an interface element attachable to the circuit carrier, featuring inner contacts and a connecting interface for peripheral connectors, allowing for automated and reliable connection of plug connectors or cables, with options for snap-fit locking and reflow soldering, enabling delayed assembly of peripheral connectors until the final fabrication step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering is used to connect peripheral contact elements to the circuit board, then reliable electrical connection is achieved, but assembly time increases and cost-efficiency decreases
Solution Approach 1:
The invention divides the connection system into separate modular components: a circuit board with integrated circuit, a peripheral contact element, and a connector housing. These segments can be manufactured independently and assembled through automated processes rather than manual soldering, resolving the contradiction between reliable connection and assembly speed.
Solution Approach 2:
The invention replaces the manual soldering process (thermal/mechanical system) with an automated connector assembly system that uses mechanical insertion and locking mechanisms. This substitution enables automated production while maintaining reliable electrical connection through the connector design.
2Adaptability or versatility
If conventional plug connectors are assembled with cables and edge connectors, then peripheral contact elements are provided, but space consumption increases
Solution Approach 1:
The invention merges the connector housing and the peripheral contact element into a single integrated component. The connector housing directly forms the peripheral contact element, eliminating the need for separate cable assemblies and edge connectors, thus reducing space consumption while maintaining full connector functionality.
Solution Approach 2:
The connector housing serves multiple functions simultaneously: it provides structural support, houses the electrical contacts, and forms the peripheral contact element itself. This multi-functionality reduces the number of separate components needed, thereby reducing overall space consumption in the sensor assembly.
3Reliability
If peripheral contact elements are manually soldered to the circuit board, then reliable electrical connection is achieved, but assembly complexity and manual labor increase
Solution Approach 1:
The invention segments the electrical connection system into a circuit board with integrated circuit and a separate connector assembly. This segmentation allows the connector to be pre-assembled and tested independently, then attached to the circuit board through simple automated processes, reducing overall assembly complexity while maintaining reliable electrical connection.
4Adaptability or versatility
If delayed assembly of peripheral connectors is implemented, then manufacturing flexibility is improved, but additional assembly steps are required
Solution Approach 1:
The invention segments the final assembly into distinct stages: circuit board preparation, connector assembly preparation, and final connection. This segmentation enables flexible timing of peripheral connector assembly while the modular design ensures that each stage is straightforward, offsetting the increased number of steps with reduced complexity per step.
Data Source
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AI summary
The present invention relates to an electrical connector kit for an electronic component and in particular for an inductive proximity sensor. Furthermore, the present invention relates to an assembly method for fabricating such an electronic component. An electrical connector kit for a circuit carrier (102) comprises at least one interface element (106) which is attachable to said circuit carrier (102) and which has at least one inner contact (108) for contacting at least one electrically conductive lead on said circuit carrier (102), said interface element (106) further comprising an electrically connecting interface (110) for contacting a peripheral connector (112, 114). A set of at least one first and second peripheral connectors (112, 114) is provided, each being connectable to said connecting interface (110), wherein, for contacting at least one external electronic component, said first and second peripheral connectors (112, 114) have peripheral contact elements (148, 152, 124) which differ from each other.