Pressure Sensor Contact Mechanism Eliminating Welding
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Solution Overview
Problem
Conventional pressure sensors require costly and time-consuming welding processes for electrical connections, which increases production costs and reduces productivity due to the need for precise micro-spot welding equipment.
Innovation Solution
A pressure sensor design that uses an electrical signal transmitting device with one end biased by an elastic member to the electrical circuit, eliminating the need for welding, and incorporates a conductive adhesive for secure contact, along with a simplified manufacturing process involving integral forming and caulking, to reduce handling time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect the terminal to the electronic circuit, then reliable electrical connection is achieved, but handling time and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. The terminal is simply pressed against the electrode pad to establish electrical contact, eliminating the need for complex welding equipment and processes. This substitution dramatically reduces manufacturing complexity and time while maintaining electrical connection reliability.
2Manufacturing precision
If laser welding equipment is used for micro-spot welding, then precise welding is achieved, but manufacturing cost increases very high
Solution Approach 1:
The patent employs a simple, inexpensive terminal structure that can be mass-produced through conventional forming processes. Instead of using expensive laser welding equipment, the solution accepts a simpler, less durable connection method (mechanical pressing) that is sufficient for the application, thereby dramatically reducing manufacturing equipment investment and operational costs.
Solution Approach 2:
The patent replaces the expensive laser welding system with a simple mechanical pressing mechanism. The terminal is pressed against the electrode pad using basic mechanical force, eliminating the need for costly laser welding equipment while achieving sufficient electrical connection for the application.
3Reliability
If welding process is performed for each pressure sensor, then electrical connection is established, but production time is lost and productivity decreases
Solution Approach 1:
The terminal is pre-formed with the appropriate shape and electrical contact surface before assembly. The pressing operation simply activates the pre-designed contact geometry, eliminating the need for time-consuming welding processes during final assembly. This preliminary preparation of the terminal structure enables rapid assembly without sacrificing connection reliability.
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 approach reduces the need for welding, lowers production costs, enhances productivity, and minimizes the risk of electrical disconnections and sensor failures by ensuring reliable electrical connections without visual verification of contact.
Implementation Method 1
a biasing unit to bias the one end of the electrical signal transmitting device to the electrical circuit
Data Source
AI summary
A pressure sensor includes: a main body case including a housing (1) and a joint (2); an electronic circuit (3) housed inside the main body case to convert detected pressure into electrical signals to send out; a connecting metal piece (5), one end (51)of which abuts on an electrode (31) of the electronic circuit (3); a terminal (4), one end (41) of which is joined to the other end (52) of the connecting metal piece (5) and the other end (42) of which is disposed outside the main body case; and a cushion (7) biasing the one end (51) to the electrode (31). The one end (51) and the electrode (31) are electrically connected by biasing force of the cushion (7), which eliminates welding, enabling manufacturing at low cost.