Modular Sensor Connector With Sliding Pogo Pin Terminals
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Solution Overview
Problem
Conventional sensor connectors require dedicated components for each sensor unit with varying numbers of poles and terminal arrangements, leading to complex production processes, increased costs, and inefficient assembly due to the need for welding and separate housing configurations.
Innovation Solution
A modular sensor connector design featuring a connector housing with a terminal module that includes a movable contact and biasing member, allowing for flexible assembly and compatibility with various sensor units without the need for welding, using a commonized terminal module that can be easily integrated into the connector housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dedicated connectors are prepared for each sensor unit repertoire, then compatibility with various sensor units is achieved, but device complexity and production cost increase
Solution Approach 1:
The patent applies universality by designing a single standardized connector structure that can accommodate multiple sensor unit repertoires. The connector uses a common housing design with standardized terminal arrangements that can interface with different sensor types (pressure sensors, temperature sensors, etc.) having different numbers of poles and terminal positions, eliminating the need for dedicated connectors for each sensor variant.
Solution Approach 2:
The patent segments the connector into modular components: a standardized housing structure, interchangeable terminal modules, and configurable internal arrangements. This segmentation allows the same basic connector framework to be adapted to different sensor repertoires by reconfiguring internal terminal positions rather than designing entirely different connectors for each application.
2Reliability
If welding process is used to connect lead terminal and connection terminal, then reliable electrical connection is achieved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical connection system. The lead terminal and connection terminal are connected through mechanical insertion and retention mechanisms within the connector housing, eliminating the need for welding operations while maintaining reliable electrical contact through direct metal-to-metal contact and mechanical retention.
Solution Approach 2:
The patent applies preliminary action by pre-assembling terminal modules within the connector housing before final assembly. The lead terminals and connection terminals are positioned and secured in their correct configurations during connector manufacturing, so that during sensor unit assembly, the terminals are already in place and ready for immediate electrical connection without requiring on-site welding operations.
3Reliability
If welding hole is provided in connector housing, then welding connection is enabled, but housing structure complexity and sealing requirements increase
Solution Approach 1:
The patent eliminates the welding hole requirement by replacing the welding process with mechanical terminal retention systems. The connector housing incorporates built-in retention features such as clips, slots, or interference-fit structures that mechanically secure the terminals in place without requiring penetration holes for welding, thereby maintaining housing integrity and simplifying the sealing requirements.
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 modular design simplifies assembly operations, reduces production costs, and enhances efficiency by allowing automatic assembly machine operations, while maintaining reliable electrical contact without the need for welding, thus improving compatibility with diverse sensor units.
Implementation Method 1
a movable contact (52) movably coupled to the module base (51); and a biasing member (53) intervening between the module base (51) and the movable contact (52)... the movable contact (52) is biased by the biasing member (53) so as to protrude from the surface of the connector housing (3) to face the sensor body (12), and the movable contact (52) is in contact with the sensor body (12) by joining the connector housing (3) to the sensor housing (11)
Data Source
AI summary
A sensor connector compatible with various sensor unit repertoires and capable of improving production efficiency is provided. The sensor connector includes terminal modules to be inserted into a module inserted portion, and commonized pogo pin type terminal module is brought into contact with a connection terminal via slide contact segments capable of sliding relative to the connection terminal exposed to a region closer to the module inserted portion. Thus, the sensor connector can be compatible with the sensor unit 1 having various repertoires by changing, for example, the arrangement and the number of poles of the module inserted portions of the connector housing.