Optical Sensor Circuit Board Mounting with Elastic Damping
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Solution Overview
Problem
Existing optical sensors face challenges in securely mounting circuit boards within housings, requiring tools and being time-consuming, and are sensitive to external vibrations and shocks, which is critical for safety sensors.
Innovation Solution
The optical sensor employs elastic material in grooves to securely position and stabilize circuit boards, using rail elements that attach to the circuit board edges, allowing for tool-free installation and enhanced shock and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections are used to secure circuit boards in housings, then the mounting is secure and stable, but the installation requires tools and is time-consuming
Solution Approach 1:
An elastic intermediate element is introduced between the circuit board and the housing groove. This elastic element serves as a mediator that provides secure mounting through elastic retention while enabling tool-free installation by allowing the circuit board to be inserted and retained without screws or clips.
Solution Approach 2:
The mechanical screw connection system is replaced with an elastic retention system. Instead of using threaded fasteners requiring rotational force, the solution uses elastic deformation and recovery to provide retention, substituting a complex mechanical fastening system with a simpler elastic engagement mechanism.
2Stability of the object's composition
If circuit boards are mounted rigidly in housings, then the position is precise and stable, but the sensor is sensitive to external vibrations and shocks
Solution Approach 1:
The elastic intermediate element is installed beforehand between the circuit board and housing groove to provide cushioning against upcoming vibrations and shocks. This pre-positioned elastic element absorbs and dampens external mechanical disturbances before they can affect the circuit board and its mounted components.
Solution Approach 2:
The mounting system transitions from rigid fixation to elastic retention, changing the mechanical parameters from zero compliance to controlled elastic compliance. This parameter change allows the system to maintain position stability under normal conditions while providing vibration and shock isolation when external forces are applied.
3Reliability
If traditional fastening methods are used for circuit boards, then secure mounting is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The elastic intermediate element combines multiple functions into a single component: it provides mechanical retention, vibration damping, shock absorption, and positional alignment. This merging of functions reduces the overall mounting structure complexity by eliminating the need for separate fasteners, mounting features, and damping elements.
Solution Approach 2:
The elastic intermediate element serves multiple purposes simultaneously: it acts as a retention mechanism, a mounting feature, a damping element, and an alignment guide. This multi-functionality reduces device complexity by replacing what would traditionally require multiple separate components with a single universal element.
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 solution ensures the circuit boards remain securely positioned and protected from external disruptions, such as shock and vibration, while allowing for quick and tool-less installation, which is crucial for safety sensors.
Implementation Method 1
These elastic elements have a shock and vibration damping effect on the circuit board and on its mounted components
Implementation Method 2
These elastic elements have a shock and vibration damping effect on the circuit board and on its mounted components
Implementation Method 3
The circuit board is mounted without play in grooves arranged in the housing with the interposition of an elastic material
Data Source
Figure 1
Figure 2
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AI summary
The invention relates to an optical sensor for detecting objects within a monitoring area, comprising sensor components and electronic components. The sensor and electronic components are arranged in at least one housing 2a or 2b, in which at least one printed circuit board (10) accommodating sensor components and/or electronic components is mounted. The printed circuit board (10) is mounted without play in grooves (12) arranged in the housing 2a or 2b, with an elastic material intermediately inserted.