Sensor Assembly Terminal Spring Force Alignment
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Solution Overview
Problem
Existing sensor assemblies for vehicle occupant restraint and safety systems face manufacturing and reliability challenges due to complex mounting processes and the need for precise alignment of leadless sensor packages with terminals, which can lead to mechanical and electrical connection issues.
Innovation Solution
A sensor assembly featuring a polymer housing with integrated terminals that provide a spring force against the leadless sensor package for secure mechanical and electrical connection, allowing for improved manufacturability and durability, and including features like crush ribs and locking mechanisms for precise alignment and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional mounting methods are used to attach sensor assemblies to circuit boards, then the assembly can be mounted, but manufacturing complexity and reliability issues increase due to complex mounting processes and precise alignment requirements
Solution Approach 1:
The patent combines the sensor package, terminals, and housing into an integrated sensor assembly unit. The terminals are pre-positioned within the housing and the sensor package is secured directly to the housing, eliminating the need for separate mounting operations. This integration reduces the number of discrete components and assembly steps, directly addressing the contradiction by simplifying manufacturing while reducing device complexity.
Solution Approach 2:
The terminals are pre-positioned and secured within the housing before the sensor package is installed. The housing is prepared with locating features and retention mechanisms in advance. This preliminary arrangement of components eliminates the need for complex real-time alignment during assembly, thereby simplifying the manufacturing process and reducing mounting complexity.
2Reliability
If traditional mounting methods are used with leadless sensor packages, then the sensor can be connected, but alignment precision and connection reliability deteriorate due to mechanical and electrical connection issues
Solution Approach 1:
The housing serves as an intermediary component between the sensor package and the terminals. It provides a stable mounting structure with integrated locating features that guide the sensor package into proper alignment with the terminals. The housing absorbs alignment tolerances and ensures consistent electrical connections, thereby improving connection reliability without requiring extremely tight manufacturing precision.
Solution Approach 2:
The sensor package and terminals are designed to self-align through complementary geometric features in the housing. The retention mechanism automatically secures the sensor package in the correct position when installed, eliminating the need for complex external alignment tools or procedures. This self-aligning design improves connection reliability while reducing the precision requirements for manual assembly.
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 solution enhances the reliability and durability of sensor assemblies by ensuring a continuous and firm physical contact between the sensor package and the housing, improving manufacturing efficiency and reducing the complexity of mounting processes.
Implementation Method 1
The terminals are inserted to provide a spring force against pads of the leadless sensor package to mechanically support an electrical connection between the leadless sensor package and the terminals
Data Source
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Figure 5A~5F
AI summary
A sensor assembly is provided with a housing, a sensor package, and terminals. The housing may Include a connector opening configured to mate with a wire harness connector. The sensor package may include conductive pads exposed in a surface of the sensor package. The terminals may be inserted into the housing and extend into the connector opening. The terminals form an electrical and mechanicai connection the conductive pads of sensor package.