Sensor Cable Press-Fit Connector for Dense PCB Mounting

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Solution Overview

Problem

As sensors miniaturize, the narrow mounting spaces on circuit boards make it difficult to solder cables reliably, leading to potential short-circuits, damage from high-temperature soldering, and variability in quality and connection reliability due to operator dependence.

Innovation Solution

A sensor design featuring a connector with pinching elements on a circuit board that pinches the cable, eliminating the need for soldering and allowing for high-density mounting, with features like pressure-contact blades and symmetrical pinching elements to ensure secure and uniform connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering is used to mount cables on the circuit board, then electrical connection is achieved, but the risk of short-circuits and damage increases when mounting space is narrow

Engineering Contradiction:

Improveconnection reliabilityVSAvoidshort-circuit risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts the harmful soldering process from the cable mounting operation. By replacing soldering with a mechanical pressing operation using the connector, the source of heat-related damage and short-circuits is removed entirely, while maintaining reliable electrical connection through the conductive connector structure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the thermal/mechanical soldering process with a purely mechanical pressing system. The connector applies mechanical pressure to establish both electrical and mechanical connections without heat, eliminating the harmful effects of soldering in narrow mounting spaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If soldering is used to mount cables, then electrical connection is established, but quality varies due to operator dependence

Engineering Contradiction:

Improveconnection reliabilityVSAvoidsoldering quality consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The connector performs the connection function automatically through its own structure. The pressing operation self-aligns and self-secures the cable and circuit board connection without requiring operator skill or judgment, making the process self-sufficient and eliminating variability from human factors.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

By replacing the skilled-manual soldering process with an automated mechanical pressing system, the invention eliminates operator dependence. The standardized connector design ensures consistent connection quality regardless of the assembler's skill level.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If soldering is used for cable mounting, then connection is achieved, but assembly time increases and requires skilled personnel

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention replaces the time-consuming, skill-dependent soldering process with a rapid mechanical pressing operation. This substitution dramatically reduces assembly time and eliminates the need for skilled soldering personnel, while maintaining connection reliability through the engineered connector design.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If mounting space for strands is increased to facilitate soldering, then soldering becomes easier, but the sensor size increases

Engineering Contradiction:

Improvesoldering easeVSAvoidsensor size

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The invention extracts the requirement for large mounting space by removing the soldering process. The compact pressing connector enables cable mounting in confined spaces that would be inaccessible to soldering irons, allowing high-density strand arrangement without increasing overall sensor volume.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By substituting soldering with mechanical pressing, the invention enables cable connection in tight spaces where soldering tools cannot reach. This allows optimal use of available mounting space and minimizes sensor size while maintaining ease of manufacture through the simple pressing operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11831119B2Sensor and sensor manufacturing method

Publication Date: 2023.11.28 OMRON CORP

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.