Satellite Housing Electrical Connector for Vehicle Sensors

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Solution Overview

Problem

The miniaturization of electronic sensor packages poses challenges in manufacturing and assembly due to smaller contact pads, reducing connection area and making it difficult to insert sensors into protective housings, while also exposing them to harsh environmental conditions in vehicles.

Innovation Solution

An enhanced remote sensor unit (RSU) with a satellite housing and an electrical connector having a capture portion with opposing mechanical contact elements and a pin portion for secure electrical connection, allowing flexibility in design, manufacturing, and assembly processes, and providing enhanced mechanical stability and protection from environmental factors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If electronic sensor packages are miniaturized to reduce size, then placement flexibility in tight vehicle spaces is improved, but manufacturing difficulty increases and connection area between sensor and interface is reduced

Engineering Contradiction:

Improveelectronic sensor package sizeVSAvoidmanufacturing and assembly difficulty

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The electrical connector is divided into distinct functional segments: a capture portion with opposing mechanical contact elements for receiving the electronic component, and a pin portion for external electrical connections. This segmentation allows each portion to be optimized independently, making assembly easier despite miniaturization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrical connector acts as an intermediary component between the miniaturized electronic sensor and the vehicle monitoring system interface. It provides mechanical support and electrical connection functionality that compensates for the reduced size of the sensor package, maintaining ease of manufacture and assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If electronic sensor packages are miniaturized, then placement flexibility in tight vehicle spaces is improved, but connection area between electronic sensor and interface is reduced

Engineering Contradiction:

Improveelectronic sensor package sizeVSAvoidconnection area

Core Design Contradiction:

Volume of moving objectVSArea of stationary object

Solution Approach 1:

The connection interface transitions from a two-dimensional contact pad on the sensor surface to a three-dimensional structure with opposing mechanical contact elements that engage with the electronic component edges. This dimensional change compensates for the reduced connection area by utilizing vertical engagement rather than relying solely on surface contact area.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If electronic sensors are positioned to optimize sensing capabilities and coverage, then performance is improved, but exposure to harsh environmental conditions increases

Engineering Contradiction:

Improvesensing performanceVSAvoidexposure to harsh environmental conditions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The electrical connector provides a protective enclosure that shields the miniaturized electronic sensor from harsh environmental conditions while maintaining the sensor's sensing capabilities. The connector housing acts as a protective barrier against moisture, dust, and mechanical damage.

Inventive Principle:

Principle #30Flexible shells and thin films

4Volume of moving object

If smaller electronic packages are used, then placement in tight spaces is improved, but mechanical stability and protection from environmental factors are reduced

Engineering Contradiction:

Improveelectronic package sizeVSAvoidmechanical stability and protection

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The electrical connector merges multiple functions into a single component: it provides mechanical support for the miniaturized sensor, ensures electrical connection, and offers environmental protection. This combination compensates for the reduced mechanical stability of smaller packages by integrating structural support functions.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2619538B1An enhanced electronic assembly

Publication Date: 2016.07.20 AUTOLIV ASP INC

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AI summary

Remote sensor units for a vehicle are described. An apparatus may comprise a satellite housing having an electrical connector interface portion, and an electrical connector disposed within the electrical connector interface portion of the satellite housing. The electrical connector may be arranged to conduct electrical signals for an electronic component having an electronic sensor operative to monitor conditions for a vehicle, the electrical connector comprising a capture portion at a first end and a pin portion at a second end, the capture portion having a pair of opposing mechanical contact elements arranged to receive at least one edge of the electronic component. Other embodiments are described and claimed.