Pressure Sensor PCB Perpendicular Mounting for Brake Reliability
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Solution Overview
Problem
Existing pressure sensors in vehicle brake systems face challenges with miniaturization and reliability due to the use of conductive adhesive connections, which do not ensure consistent functioning over the vehicle's service life.
Innovation Solution
A compact and robust pressure sensor design with a printed circuit board arranged perpendicular to the base, using mechanical and electrical connections such as bonded, welded, or soldered connections, and a symmetrical placement to absorb external forces, along with a protective sleeve for component protection, ensuring reliable and durable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductive adhesive connections are used in pressure sensors, then assembly is simplified, but reliability over service life deteriorates
Solution Approach 1:
The patent replaces conductive adhesive connections with mechanical electrical connections using contact rivets and contact elements. The contact rivets provide reliable electrical and mechanical connections between the pressure measuring cell and the circuit carrier, eliminating the unreliability of conductive adhesives while maintaining ease of assembly through standardized connection mechanisms.
2Volume of moving object
If pressure sensor components are miniaturized, then compactness is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The patent divides the pressure sensor into distinct functional modules: a pressure measuring cell, a circuit carrier with integrated contact elements, and a printed circuit board. This segmentation allows each component to be manufactured separately with standard precision, then assembled into a compact unit, reducing the overall size without demanding extreme precision across the entire assembly.
Solution Approach 2:
The printed circuit board is arranged perpendicular to the base plane with its focal point on the longitudinal axis, nesting components efficiently. The contact rivets are integrated into the circuit carrier structure, and electrical connections are routed through existing structural elements, maximizing space utilization and achieving miniaturization without proportionally increasing precision requirements.
3Volume of moving object
If printed circuit board is arranged perpendicular to base plane, then compactness is improved, but mechanical strength may worsen
Solution Approach 1:
The printed circuit board is deliberately positioned asymmetrically relative to the base plane, perpendicular to it with its focal point on the longitudinal axis. This asymmetric arrangement optimizes the footprint and allows components to be arranged on both sides of the board, achieving compactness. The asymmetric position is compensated by the robust mechanical design of the circuit carrier and connecting elements that anchor the PCB securely.
Solution Approach 2:
The circuit carrier is designed with pre-integrated contact elements and mounting features that establish secure mechanical anchors before the printed circuit board is installed. This preliminary structural preparation ensures that when the PCB is positioned perpendicular to the base plane, the overall assembly maintains sufficient mechanical strength through the pre-established connection framework.
4Ease of repair
If contact rivets with detachable connection are used, then ease of repair is improved, but device complexity worsens
Solution Approach 1:
The contact rivet connection system is designed to be self-contained and self-explanatory, with the contact elements and rivets forming an intuitive mechanical interface. The detachable connection allows for easy repair and replacement without requiring complex tools or procedures, while the standardized design keeps the overall complexity manageable. The connection mechanism serves itself through its simple, standardized interface that can be manually operated.
Data Source
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AI summary
The invention relates to a pressure sensor for detecting a pressure of a medium, comprising a connecting flange (3) with a channel (33) for connecting to the medium to be measured, a pressure gauge (2), to which the pressure can be fed via the channel (33), and a printed circuit board (4) which is arranged in such a way that the printed circuit board lies in a longitudinal axis (X-X) of the pressure sensor.