Optical Sensor PCB Mounting With Elastic No-Play Retention
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Solution Overview
Problem
Existing optical sensors require time-consuming and tool-dependent fastening methods to secure printed circuit boards, which are not robust against environmental vibrations and shocks.
Innovation Solution
The optical sensor employs a deformable printed circuit board that is mounted in a receptacle without play, using spring-loaded joints or flexible edges to secure the board in place without tools, ensuring stable positioning even under external loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections are used to secure circuit boards, then the mounting is robust, but the installation is time-consuming and requires tools
Solution Approach 1:
The circuit board's own elastic edges serve as the fastening mechanism. When the circuit board is inserted into the receptacle, its elastic edges automatically deform and engage with the receptacle walls, creating a self-fastening connection that requires no external tools or additional fastening components.
Solution Approach 2:
The circuit board edges are designed with elastic properties that allow them to change shape during insertion. The edges deform elastically when entering the receptacle and then return to their original shape, creating a secure mechanical engagement through controlled parameter change (shape deformation).
2Reliability
If screw connections are used to secure circuit boards, then the mounting is secure, but the process is complex and tool-dependent
Solution Approach 1:
The circuit board itself provides the fastening function through its elastic edges, eliminating the need for separate fastening components or complex assembly processes. The board's own structural properties are utilized to create the secure connection.
Solution Approach 2:
The functional separation between the circuit board (electronic component carrier) and the fastening mechanism is eliminated. The circuit board's edges simultaneously serve as structural support and as the fastening element, merging two functions into a single integrated solution.
3Reliability
If rigid circuit boards are used, then the electrical connections are stable, but the mounting requires tools and is time-consuming
Solution Approach 1:
Only specific localized regions of the circuit board (the edges) are given elastic properties, while the main board body remains rigid to maintain electrical connection stability. This localized quality change allows the board to be both rigid for electrical stability and elastic for easy mounting.
Solution Approach 2:
The circuit board is functionally segmented into rigid regions (for electrical connections) and elastic regions (for mounting). The edges are specifically designed as elastic segments that can deform during insertion while the rest of the board maintains its rigid structure for stable electrical connections.
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 method allows for quick, tool-free installation and secure mounting of circuit boards, maintaining precise positioning and electrical contacts, even under environmental stress, particularly important for safety sensors.
Implementation Method 1
elements on the printed circuit board are deformed when the printed circuit board is inserted into a desired position in the receptacle. The elements on the printed circuit board are deformable in the receptacle such that they are mounted in the receptacle without play.
Data Source
Figure 1
Figure 2a~2c
Figure 3a~3e
AI summary
The invention relates to an optical sensor for detecting objects within a monitoring area, comprising sensor components and electronic components arranged in at least one housing 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 in a recess of the housing without play such that, when the printed circuit board (10) is inserted into a predetermined position in the recess, elements of the recess or elements of or on the printed circuit board are deformed.