Multi-Board Sensor Layout for Compact Housing and Precise Positioning
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Solution Overview
Problem
The existing sensor designs face challenges in accommodating multiple circuit substrates in a compact manner, limiting the size of the circuit substrates that can be disposed and increasing the thickness of the mounting space, which hinders the miniaturization of the housing and the facilitation of optical properties.
Innovation Solution
A sensor configuration featuring a base member with projection parts and positioning pins with ribs, allowing precise positioning of multiple rigid substrates close to each other, minimizing the mounting space, and using a rigid flexible substrate to connect the substrates without additional connectors, enabling efficient heat dissipation and compact accommodation of circuit substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple circuit substrates are disposed in parallel arrangement, then the sensor can detect various work pieces with complicated processes, but the thickness of the mounting space increases
Solution Approach 1:
The patent transitions from parallel arrangement (same plane) to perpendicular arrangement (different planes/dimensions). The first circuit substrate is disposed on the right side surface while the second circuit substrate is disposed on the upper surface, utilizing three-dimensional space to reduce mounting space thickness while maintaining the ability to accommodate multiple substrates for versatile detection
2Volume of stationary object
If the mounting space of the circuit substrate is reduced to minimize housing size, then the housing can be miniaturized, but the positioning precision of multiple substrates becomes more difficult to achieve
Solution Approach 1:
The patent introduces a base member as an intermediary component that provides precise positioning features (protrusions, recesses, positioning holes) to accurately locate and fix multiple circuit substrates in their respective positions. This mediator enables precise positioning even when the overall mounting space is minimized, as the base member contains all necessary positioning structures
Solution Approach 2:
The base member is pre-designed with integrated positioning features (protrusions, recesses, positioning holes) before assembly. This preliminary preparation of positioning structures ensures that when substrates are assembled, they automatically achieve precise positioning without requiring additional adjustment or complex manufacturing processes
3Volume of stationary object
If the upper surface is used to dispose circuit substrates to reduce housing size, then the housing can be compact, but the size of the circuit substrate that can be disposed is limited due to narrower surface area
Solution Approach 1:
The patent utilizes multiple surfaces (right side surface and upper surface) in three-dimensional space rather than relying on a single two-dimensional plane. This allows circuit substrates of appropriate sizes to be disposed on each surface while maintaining a compact overall housing volume, effectively bypassing the area limitation of a single narrow surface
Data Source
AI summary
A base member of the sensor includes a first projection part, a second projection part, and a third projection part, being columnar and projecting from a first placement surface. Tip ends of the first, second and third projection parts are formed on second placement surfaces. The first and second projection parts respectively include a fourth pin and a fifth pin inserted through a second rigid substrate and projecting from the second placement surface. Three ribs are formed on a peripheral surface of the fourth pin and disposed so that positions viewed from a center of the fourth pin respectively form angles less than 180 degrees. Two ribs are formed on a peripheral surface of the fifth pin, and project along a fourth line perpendicular to a third line connecting the fourth pin and the fifth pin.