Sensor Terminal Structure for Noise Reduction and Soldering Precision

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Solution Overview

Problem

Existing sensors face challenges in reducing external electrical noise and preventing damage to electronic components during the production process, particularly when implementing π-type filters, due to difficulties in accurate soldering and stress application during terminal connection and cutting.

Innovation Solution

The sensor design includes an integrated circuit with a power supply lead, ground lead, and signal lead, along with a filter member and a sealing body that exposes parts of the power supply terminal, ground terminal, first signal terminal, and second signal terminal, allowing for easier integration and connection of terminals, reducing positional deviations, and minimizing stress on components during cutting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the signal terminal is divided into two parts and a resistor is connected between them during soldering, then a π-type filter can be provided to reduce electrical noise, but accurate soldering becomes difficult due to relative movement between components

Engineering Contradiction:

Improveelectrical noiseVSAvoidsoldering accuracy

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The signal terminal is divided into two parts (first signal terminal and second signal terminal) that are preliminarily positioned and fixed relative to each other before soldering. The resistor is then soldered between these pre-positioned terminals, eliminating the problem of relative movement during soldering while still achieving the π-type filter configuration for noise reduction.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If the signal terminal is cut off after soldering electronic components and a resistor is connected to the cutting portion, then a π-type filter can be provided, but stress is applied to already soldered components causing potential damage

Engineering Contradiction:

Improveelectrical noiseVSAvoidcomponent integrity

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The signal terminal is divided into two parts that are preliminarily positioned and fixed relative to each other before soldering. The resistor is then soldered between these pre-positioned terminals, eliminating the problem of relative movement during soldering while still achieving the π-type filter configuration for noise reduction.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If the signal terminal is cut off during the soldering process to connect a resistor, then a π-type filter can be provided, but the production process becomes more difficult

Engineering Contradiction:

Improveelectrical noiseVSAvoidproduction difficulty

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

4Object-affected harmful factors

If multiple terminals are connected during assembly, then electrical noise can be reduced with a π-type filter, but positional deviations and terminal floating occur

Engineering Contradiction:

Improveelectrical noiseVSAvoidterminal positioning accuracy

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The first signal terminal and second signal terminal are merged into a single integrated terminal structure with a fixed relative position. This unified terminal is then connected to the integrated circuit as one unit, eliminating positional deviations and terminal floating while still allowing the resistor to be connected between the two parts for π-type filter functionality.

Inventive Principle:

Principle #5Merging (Combining)

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 configuration effectively reduces external electrical noise, simplifies the production process by preventing terminal floating and positional deviations, and minimizes the risk of component breakage during production.

Implementation Method 1

a sealing body that seals the integrated circuit, the power supply terminal, the ground terminal, the first signal terminal, the second signal terminal and the filter member

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS10199567B2Sensor and method for producing same

Publication Date: 2019.02.05 DENSO CORP

AI summary

A sensor includes: an integrated circuit having a power supply lead, a ground lead and a signal lead; a power supply terminal connected to the power supply lead; a ground terminal connected to the ground lead; a first signal terminal connected to the signal lead; a second signal terminal connected to the first signal terminal; a filter member having one end connected to one of the terminals and another end connected to another one of the terminals; and a sealing body sealing the integrated circuit, the terminals and the filter member. A part of each terminal is exposed from the sealing body.