Capacitive Proximity Sensor Piercing Contact Assembly

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Solution Overview

Problem

Existing electronic units, such as capacitive proximity sensors in vehicles, face challenges in providing a reliable and cost-effective contact between flat conductor electrodes and circuit boards, often requiring complex soldering processes that complicate assembly and automation.

Innovation Solution

The electronic unit employs a piercing contact that projects from the circuit board to form an electrical connection with a flat conductor, allowing for a simple and mechanical connection without soldering, using a supporting contour to secure both the conductor and circuit board, enabling automated assembly and strain relief.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional wire or braided lines with plug connections or solder connections are used to connect the flat conductor electrode to the electronic unit, then reliable electrical connection is achieved, but the assembly process becomes complex and time-consuming

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the connection function from complex multi-step processes (soldering, plugging) and concentrates it into a single integrated piercing contact element that simultaneously provides mechanical support and electrical connection through one insertion action

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The piercing contact merges multiple functions (mechanical support, electrical connection, strain relief) into a single component that performs all these functions simultaneously during one assembly operation, eliminating the need for separate soldering or plugging steps

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If solder connections are used to connect the feed lines to the flat conductor electrode and electronic unit, then reliable electrical connection is achieved, but the assembly cannot be easily automated

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly automation capability

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The patent replaces the thermal-mechanical soldering process with a purely mechanical piercing insertion process that can be easily automated using standard insertion tools, eliminating the need for soldering equipment and processes while maintaining connection reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If plug connectors are used to connect the feed lines to the electronic unit, then assembly is simplified, but the connection occupies additional space and increases device dimensions

Engineering Contradiction:

Improveassembly easeVSAvoiddevice volume

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The piercing contact merges the mechanical support function and electrical connection function into a single integrated component, eliminating the need for separate plug connectors and reducing the overall space required for connections

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If conventional wire feed lines are used to connect the flat conductor electrode to the electronic unit, then flexibility is achieved, but the connection requires additional components and assembly steps

Engineering Contradiction:

Improveconnection flexibilityVSAvoidconnection structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts the essential functions (mechanical support and electrical connection) from the complex conventional feed line assembly and implements them through a single piercing contact, eliminating unnecessary intermediate components while maintaining connection flexibility

Inventive Principle:

Principle #2Taking out (Extraction)

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

This solution facilitates a straightforward, automated assembly process for capacitive proximity sensors by establishing both electrical and mechanical connections between the conductor and circuit board, eliminating the need for soldering and enhancing production efficiency.

Implementation Method 1

at least one piercing contact projecting (down) from the circuit board and electrically connecting the conductor to the electronic assembly, the piercing contact penetrating the connection end and forming an electrical connection with the conductor track of the conductor

Methodology Applied

Scientific EffectMechanical penetration: Mechanical Force

Data Source

PatentUS9543674B2Electronic unit, in particular capacitive proximity sensor

Publication Date: 2017.01.10 BROSE FAHRZEUGTEILE GMBH & CO KG

AI summary

An electronic unit has an electronic assembly that comprises a circuit board, and also having a conductor that is connected to said electronic assembly and is provided with a flat connection end. At least one piercing contact protrudes down from the circuit board and connects the conductor electrically to the electronic assembly. The piercing contact penetrates the connection end of the conductor while forming an electrical connection with a conductor track of the conductor. The electronic component is particularly suited as a capacitive proximity sensor for a vehicle.