Sensor Cable Connector with Pinching Elements for Solder-Free PCB Mounting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

As sensors become smaller, the increased number of components on circuit boards narrows the mounting space, leading to issues such as solder bridging between adjacent strands, damage from high-temperature soldering, and variability in soldering quality and reliability due to operator dependence.

Innovation Solution

A sensor design featuring a connector with pinching elements that securely attach a cable to the circuit board without soldering, allowing for high-density mounting and reliable connection through pinching and pressure-contact blades.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering is used to mount strands on the circuit board, then electrical connection is achieved, but the risk of solder bridging between adjacent strands increases and soldering quality varies due to operator dependence

Engineering Contradiction:

Improveconnection reliabilityVSAvoidsoldering quality consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces the thermal soldering process with a mechanical pressing system. A pressing element applies downward force to deform the strand and create a mechanical interlock with the circuit board, eliminating the need for soldering operations and associated quality variability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The strand itself serves as the connecting element by being deformed to create a mechanical interlock. The strand's own material properties are utilized to achieve both electrical connection and mechanical fixation, eliminating the need for separate soldering materials and processes.

Inventive Principle:

Principle #25Self-service

2Productivity

If the interval between adjacent strands is narrowed to increase mounting density, then miniaturization is enabled, but solder may flow to adjacent strands causing short-circuits or high-temperature soldering irons may contact strands causing damage

Engineering Contradiction:

Improvemounting densityVSAvoidsolder bridging and thermal damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates the high-temperature soldering process entirely by using a mechanical pressing system. This allows strands to be placed much closer together without the risk of solder bridging or thermal damage, as no molten solder or hot soldering iron is involved.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If soldering operations are performed manually, then flexibility in assembly is maintained, but work time increases and quality varies depending on operator skill

Engineering Contradiction:

Improveassembly flexibilityVSAvoidassembly speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The pressing element automatically performs the connection function when activated. The system is designed so that the act of pressing simultaneously achieves both the mechanical deformation of the strand and the electrical connection, eliminating the need for separate manual soldering operations.

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP3890117B1sensor

Publication Date: 2026.01.07 OMRON CORP

Figure 1
Figure 2
Figure 3

AI summary

Provided is a sensor which makes it easy to mount a cable to a circuit board. This sensor 1 is provided with: a circuit board 2; a connector 10 which is composed of a metal material and which is fixed to the circuit board 2; and a cable 3 which is connected to the circuit board 2 via the connector 10. The connector 10 has: a bottom part 11 that is connected to the circuit board 2; and a pair of pinching elements 12L, 12R that are raised upright from said bottom part 11. The cable 3 is held in a space S between the pair of pinching elements 12L, 12R.