Radar Sensor Housing Connector Module With Resilient Contact
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Solution Overview
Problem
Existing radar sensor units face challenges in achieving an uncomplicated and reliable connector arrangement for housing components, such as PCBs and antenna devices, while also requiring electromagnetic shielding and easy assembly.
Innovation Solution
The radar sensor unit incorporates a housing with a connector module featuring resilient compressible eye parts and hook members for secure electrical and mechanical contact, along with an intermediate metal layer for EMI shielding, and uses press-fitting or adhesive attachment for assembly, with optional integrated guiding pins and an antenna shield for enhanced stability and shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional connectors with multiple separate components are used, then electrical connection is achieved, but the connector arrangement becomes complicated and assembly becomes difficult
Solution Approach 1:
The patent combines multiple connector components (contact element, contact spring element, and locking mechanism) into an integrated connector module that is pre-assembled as a single unit. This module includes a housing with guide elements and locking elements that engage with corresponding features on the PCB, simplifying the connector arrangement while maintaining reliable electrical and mechanical connection.
Solution Approach 2:
The connector system is segmented into modular components: a connector module that can be independently assembled and tested, and a receiving connector on the PCB. This segmentation allows for easier manufacturing, quality control, and assembly while ensuring reliable connection through precise mating of standardized interfaces.
2Object-affected harmful factors
If electromagnetic shielding is added to protect components, then EMI protection is improved, but the housing assembly becomes more complex
Solution Approach 1:
The cover lid is designed to serve multiple functions simultaneously: it acts as a mechanical cover for the housing, provides electromagnetic shielding through integrated metal layers or shielding materials, and incorporates guide elements for component alignment. This multi-functionality reduces overall assembly complexity while maintaining effective EMI protection.
Solution Approach 2:
The housing employs composite construction with plastic housing parts combined with metal shielding layers or metal inserts. This composite approach provides both mechanical protection and electromagnetic shielding in a single integrated structure, avoiding the need for separate shielding components and simplifying assembly.
3Manufacturing precision
If precise alignment features are added for PCB mounting, then manufacturing precision is improved, but the number of components and assembly steps increases
Solution Approach 1:
The connector module and housing are pre-equipped with integrated guide elements (such as guide pins or alignment ribs) that automatically align components during assembly. This preliminary provision of alignment features ensures precise PCB mounting without requiring additional separate alignment components or complex multi-step alignment procedures.
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 configuration provides a reliable and uncomplicated connector arrangement, effective EMI shielding, and simplified assembly, ensuring the protection of internal components against mechanical and environmental damage.
Implementation Method 1
each connector pin part comprises a resilient compressible eye part that is arranged to be compressed when inserted into a corresponding eye aperture comprised in the receiving pin connector. The compressible eye part is arranged to be resiliently pressed against a corresponding conductor comprised in the receiving pin connector such that electrical contact is obtained
Implementation Method 2
For such a housing it may be desired to obtain electromagnetic shielding for some components
Implementation Method 3
the cover lid and the main housing part are attached to each other by means of at least one of: press-fitting between the housing sides and the cover sides; an adhesive
Data Source
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AI summary
The present disclosure relates to a radar sensor unit (3, 4) comprising a housing (8) and at least a first circuit board (11, 12) (PCB) arranged to be mounted in the housing (8). The housing (8) comprises a connector module (14), a main housing part (9) and a cover lid (10) that is arranged to cover the main housing part (9). The connector module (14) comprises one or more connector pin parts (16, 17, 18, 19, 20) that are arranged to protrude into the housing (8) and make electrical and mechanical contact with a receiving pin connector (21). Said electrical and mechanical contact is obtained by means of resilient pressure between said connector pin parts (16, 17, 18, 19, 20) and the receiving pin connector (21).