Optical Sensor PCB Snap-In Assembly
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Solution Overview
Problem
The high design and assembly effort required for optical sensors, particularly in configuring and connecting multiple printed circuit boards within a housing, involves expensive connectors and labor-intensive soldering and mechanical fixing processes.
Innovation Solution
A connecting element with resilient contact elements forms a snap-in connection between printed circuit boards, eliminating the need for separate connectors and soldering by ensuring precise mechanical and electrical alignment, thus reducing assembly complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connectors and soldering are used to connect printed circuit boards, then reliable electrical connection is achieved, but assembly effort and cost increase significantly
Solution Approach 1:
The patent combines mechanical connection and electrical connection functions into a single integrating element. This element features contact elements that simultaneously provide mechanical support and electrical conductivity, eliminating the need for separate connectors and soldering processes. The contact elements are designed with both mechanical engagement features and conductive pathways, achieving dual functionality in one component.
Solution Approach 2:
The integrating element serves multiple functions: it provides mechanical fixation of printed circuit boards, establishes electrical connections between boards, and ensures proper alignment. The contact elements within this element perform both structural support and electrical conduction roles, making the system more efficient by reducing the number of specialized components needed.
2Adaptability or versatility
If multiple printed circuit boards are integrated in a housing, then sensor functionality is enhanced, but design and assembly effort increase
Solution Approach 1:
The patent divides the sensor system into modular printed circuit board units that can be independently manufactured and then assembled. Each board contains specific sensor components (transmitters or receivers), allowing flexible configuration of the overall sensor system by combining different numbered boards in various arrangements within the housing.
Solution Approach 2:
The integrating element merges multiple connection functions into a single component that works with the modular board structure. This element provides standardized mechanical and electrical interfaces that simplify the assembly of multiple boards, reducing the complexity that would otherwise arise from connecting numerous separate components.
3Reliability
If precise alignment of printed circuit boards is required, then connection reliability is improved, but assembly precision requirements increase
Solution Approach 1:
The contact elements within the integrating element are designed to self-align and self-adjust during the assembly process. The mechanical features of the integrating element guide the printed circuit boards into proper alignment automatically, and the contact elements accommodate minor position variations through their design, ensuring reliable electrical connection without requiring extremely tight manufacturing tolerances.
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 significantly lowers the assembly effort and cost by establishing a secure, reproducible, and vibration-resistant electrical connection between printed circuit boards without requiring additional components or soldering, while being insensitive to component tolerances.
Implementation Method 1
the connecting element having contact elements which form an electrically conductive connection when the mechanical connection of the printed circuit boards is established
Implementation Method 2
The contact elements of the connecting element are designed to be resilient or elastically deformable
Data Source
Figure 1
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AI summary
The optical sensor, to detect objects in an observation zone, has two circuit boards (7) with sensor transmitter (3) and receiver (5) components forming a light grid (1) assembly. The boards are fixed in nominal positions by fasteners (8). The fasteners have contacts to lie against circuit board electrically conductive contact surfaces when the boards are mechanically bonded together.