Sensor Assembly Isolation Using Elastic Material and Friction Features
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Solution Overview
Problem
Conventional vibration and shock isolation systems for sensors are often impractical due to size constraints in applications like aircraft, projectiles, and vehicles, where space limitations prevent the implementation of isolators necessary for proper sensor operation.
Innovation Solution
A sensor assembly that uses a housing with printed circuit board assemblies (PCBAs) clamped between top and bottom housings, with elastic material on either side to maintain alignment and provide isolation, featuring three-dimensional features to increase friction and prevent slippage, thus eliminating the need for separate isolators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vibration and shock isolation systems are used, then sensor protection from kinetic environments is improved, but product size increases beyond acceptable limits
Solution Approach 1:
The patent combines the isolation function with the housing structure itself. The housing includes integrated isolation features such as compliant mounts and flexible sections that directly provide vibration and shock protection without requiring separate isolator components. This merging of functions eliminates the need for additional isolation devices while maintaining sensor protection.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support, environmental protection, and vibration/shock isolation. The isolation features are built into the housing design, allowing the same component to perform both structural and protective roles, thereby eliminating the need for separate isolators and reducing overall product size.
2Reliability
If separate isolators are added to protect sensors, then vibration and shock isolation is improved, but device complexity increases
Solution Approach 1:
The isolation functionality is merged into the housing structure rather than being implemented as separate isolator components. The housing includes compliant mounts, flexible sections, and integrated damping features that provide vibration and shock protection without requiring additional isolation devices, thereby simplifying the overall system architecture.
3Reliability
If elastic material is used for isolation, then vibration damping is improved, but friction between components may cause misalignment
Solution Approach 1:
The patent applies different surface characteristics to different areas of contact between the elastic material and PBA. Specifically, certain contact surfaces are engineered with higher friction properties to prevent slippage and maintain alignment, while other areas maintain the elastic material's natural low-friction characteristics for optimal vibration damping. This localized differentiation of surface properties allows simultaneous achievement of both vibration isolation and alignment precision.
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
The sensor assembly effectively isolates sensors from vibrations and shocks, maintains alignment across different environments, and reduces overall product size and cost by integrating thermal and electrical conductivity into the elastic material, making it adaptable and competitive.
Implementation Method 1
at least one piece of elastic material that is located in between the top housing and the PBA and in between the bottom housing and the PBA
Implementation Method 2
A top surface of the PBA and a bottom surface of the PBA each have at least one three-dimensional feature that is designed to increase friction with the elastic material
Data Source
AI summary
A sensor assembly is disclosed. The sensor assembly includes a housing that includes a top housing and a bottom housing that clamp together. The sensor assembly also includes a printed circuit board assembly (PBA). The sensor assembly also includes at least one piece of elastic material that is located in between the top housing and the PBA and in between the bottom housing and the PBA. When the PBA is clamped in the housing, the sensor assembly allows the PBA to maintain alignment relative to the housing across different environments in order to enable proper operation of the sensor assembly. A top surface of the PBA and a bottom surface of the PBA each have at least one three-dimensional feature that is designed to increase friction with the elastic material.