Resin Protected Sensor with Protruding Studs

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Solution Overview

Problem

Existing protective methods for electronic components in automotive applications, such as immersion in resin, are prone to cracking due to temperature and pressure variations, leading to exposure and oxidation of welds or tracks, which reduces the component's lifespan.

Innovation Solution

A housing with a cavity filled with resin, where the electronic component rests on studs protruding from the bottom, ensuring the sensitive element is exposed while the resin extends up to the side wall, and the studs are spaced more than 1 mm from the side wall or in contact with it, preventing bubble formation and subsequent cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electronic component is immersed in resin to protect it from the external environment, then the protection against environmental factors is improved, but air bubbles may form in the resin causing cracks that reduce the component's lifespan

Engineering Contradiction:

Improveprotection against environmental factorsVSAvoidair bubbles and cracks in resin

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The stud is positioned in advance during component assembly, creating a predetermined pathway that guides resin flow and prevents bubble entrapment before the resin pouring process begins

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The stud acts as an intermediary element between the electronic component and the resin, facilitating proper resin distribution and preventing bubble formation by serving as a flow guide and deaeration pathway

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of stationary object

If the stud is placed close to the side wall to maximize space utilization, then the housing capacity is improved, but air bubbles may form between the stud and side wall causing cracks

Engineering Contradiction:

Improvehousing capacityVSAvoidair bubbles between stud and side wall

Core Design Contradiction:

Volume of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The spacing requirement applies specifically to the critical region near the side wall where bubble entrapment is most likely, while other regions of the housing can maintain tighter spacing to optimize capacity

Inventive Principle:

Principle #3Local quality

3Reliability

If the resin is poured to completely cover the electronic component for maximum protection, then the environmental sealing is improved, but the sensitive element cannot be exposed to its environment

Engineering Contradiction:

Improveenvironmental sealingVSAvoidsensor functionality

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The resin coverage is applied selectively - fully covering most of the electronic component for protection, while deliberately leaving the sensitive element exposed to maintain its environmental sensing capability

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3080556B1Device comprising a resin protected sensor

Publication Date: 2018.10.17 SC2N SA

Figure 1~3

AI summary

The present invention concerns a device comprising: -a casing (10) comprising a side wall and a bottom (18) so as to define a cavity (12); - a resin (14) filling the cavity in such a way as to submerge the electronic component, leaving said sensitive element protruding. -an electronic component (32) comprising a sensor (34) provided with a sensitive element (36); -the electronic component resting on at least one pad (30) protruding from said side wall or from said bottom, so as to prevent air bubbles from forming in the resin, the pad being separated from the side wall (16) by a distance d greater than 1 mm or in contact with the side wall (16).