Segmented Proximity Sensor Housing With Flexible PCB Bending
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Solution Overview
Problem
Conventional proximity sensors have limited flexibility along their length expansion, making them rigid and prone to damage during external movements or bending, which compromises detection reliability and poses a risk of damage, especially in applications with limited space or robotic systems.
Innovation Solution
The sensor housing is designed with multiple segments linked via pivot axes, allowing for bending, and a flexible circuit board is integrated within these segments to enhance flexibility and protect the detection circuitry from mechanical impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sensor housing is made rigid to ensure structural stability and protection, then the sensor can maintain its shape and protect internal components, but the sensor cannot bend or adapt to curved surfaces or limited spaces
Solution Approach 1:
The housing is divided into multiple segments (first segment, second segment, third segment) that can move relative to each other around pivot axes. This segmentation allows the housing to bend and adapt to curved surfaces while each individual segment maintains structural integrity and protection for internal components.
Solution Approach 2:
The housing transitions from a static rigid structure to a dynamic articulated structure with pivot axes enabling relative movement between segments. This dynamic design allows the sensor to adapt its shape while maintaining protective enclosures for sensitive components within each segment.
2Reliability
If the detection circuitry is placed on a rigid circuit board to ensure electrical stability and signal quality, then the electrical connections remain stable, but the circuit board cannot withstand bending forces and may break
Solution Approach 1:
A flexible circuit board is used instead of a rigid one, allowing the electrical connections to bend with the housing segments while maintaining electrical stability. The flexible circuit board can withstand the bending forces generated by segment movement without breaking.
Solution Approach 2:
The flexible circuit board is nested within the movable segments of the housing, protected by the segment structure while allowing relative movement. This nesting arrangement protects the circuit board from external damage while enabling the housing to bend.
3Reliability
If the sensor is positioned with its front portion facing the object to ensure proper detection function, then the sensing element can interact with the object effectively, but the sensor cannot be freely oriented or adapted to different mounting positions
Solution Approach 1:
The segmented housing with pivot axes allows the sensor to be mounted in various orientations and positions while maintaining the front portion's ability to face the object. The segments can articulate to achieve different mounting configurations.
Solution Approach 2:
The articulated housing structure provides multi-functional mounting capabilities, allowing the sensor to be installed on flat surfaces, curved surfaces, and in limited spaces while maintaining proper detection function. The same basic structure adapts to multiple mounting scenarios.
4Ease of manufacture
If the sensor housing is made long to accommodate detection circuitry behind the sensing element, then the electrical connections and components can be properly arranged, but the sensor becomes too long for applications with limited space behind the object
Solution Approach 1:
The detection circuitry is distributed across multiple segmented sections rather than requiring a long continuous housing. Each segment can be compact while the articulated connection allows the overall sensor to maintain proper component arrangement without excessive length.
Solution Approach 2:
Instead of extending the sensor length in one dimension to accommodate circuitry, the segmented design allows components to be arranged in a folded or articulated configuration, effectively using spatial arrangement in multiple dimensions to reduce the overall length requirement.
Data Source
AI summary
The present disclosure relates to a proximity sensor for detecting the proximity of an object, the sensor including a sensing element (11), a detection circuitry (65), and a housing (5), the sensing element (11) being arranged in a front portion (21) of the housing (5) such that it is adapted to interact with the object through the front portion (21) and the detection circuitry being interconnected with the sensing element (11) in order to receive a detection signal from the sensing element (11), wherein the detection circuitry (65) is provided on a circuit board (15, 15A, 15B, 15C) extending at least through a middle portion (22) of the housing (5).To allow a better flexibility of the sensor along its length expansion, it is proposed that the housing (5) includes multiple segments (41, 42, 43, 44) that are consecutively arranged in a longitudinal direction (27) from a rear end (56) toward a front end (55) of the housing (5), wherein neighboring segments of said segments (41, 42, 43, 44) are linked to each other via a respective pivot axis (35, 39, 40) extending transversely with respect to said longitudinal direction (27), such that the housing (5) is bendable around each of said pivot axes (35, 39, 40), wherein both of said front portion (21) and said middle portion (22) each includes at least one of said segments (41, 42, 43, 44), and wherein the circuit board (15, 15A, 15B, 15C) includes at least one bendable section (61, 75, 76, 77, 85, 86) extending transversely with respect to said longitudinal direction (27), said bendable section (61, 75, 76, 77, 85, 86) being provided inside said neighboring segments (41, 42, 43, 44).