Shaped Circuit Board for Locking Device Sensor Integration
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Solution Overview
Problem
Existing mechanical locking devices face challenges in integrating electronic components without significant mechanical redesign, particularly in terms of wire routing and positioning of switches and actuators, leading to performance limitations and increased costs.
Innovation Solution
A specially shaped printed circuit board with a non-rectangular perimeter is designed to fit within or onto the locking device, allowing for precise positioning of sensors and actuators while minimizing interference with mechanical components and providing efficient wiring solutions, enabling the 'electrification' of mechanical locks with minimal modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual sensing switches and actuators are mounted within the locking device with discrete wiring, then electronic functionality is achieved, but component design differences increase and manufacturing cost increases
Solution Approach 1:
The patent merges multiple electronic components (sensors, actuators, wiring) onto a single printed circuit board that is integrated into the locking device housing. This consolidation eliminates the need for separate mounting of individual components and discrete wiring, thereby reducing manufacturing complexity and cost while maintaining electronic functionality.
Solution Approach 2:
The printed circuit board serves multiple functions simultaneously: it provides structural support, electrical connectivity, mounting for electronic components, and integration with the mechanical locking mechanism. This multi-functionality reduces the number of separate parts needed, simplifying manufacturing and reducing costs.
2Adaptability or versatility
If individual sensing switches and actuators are mounted within the locking device, then electronic sensing and actuation are enabled, but packaging limitations are imposed
Solution Approach 1:
By combining multiple electronic components onto a single printed circuit board, the patent reduces the number of separate items that need to be packaged within the locking device. This integration simplifies the packaging arrangement while enabling comprehensive electronic sensing and actuation capabilities.
Solution Approach 2:
The printed circuit board is nested within the locking device housing, with components mounted on the board positioned to interact with mechanical elements. This nesting arrangement efficiently utilizes the available space within the locking device while maintaining all necessary electronic functions.
3Ease of manufacture
If a standard rectangular circuit board is used, then manufacturing is simplified, but the board cannot be positioned close to moving components without interference
Solution Approach 1:
The patent uses a non-rectangular circuit board shape that is specifically designed to fit the contours of the locking device housing and accommodate the positions of moving components. This asymmetric shape allows the board to be positioned close to moving components for optimal sensing and actuation while avoiding interference, departing from the standard rectangular form for functional reasons.
4Ease of operation
If the circuit board is shaped to fit the locking device, then component positioning is improved, but manufacturing complexity increases
Solution Approach 1:
While the non-rectangular shape does increase manufacturing complexity compared to a standard board, the patent justifies this by demonstrating that the asymmetric shape enables precise positioning of electronic components relative to moving mechanical parts, which is critical for the proper operation of the locking device. The manufacturing complexity increase is acceptable given the significant improvement in component positioning and overall device functionality.
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 approach allows for efficient implementation of precise sensing and actuation in locking devices with reduced costs and complexity, enabling the integration of multiple electronic components on a single board without the need for extensive redesign or complex wiring harnesses.
Implementation Method 1
at least one non-contact sensor, such as a magnetically operated reed switch or a Hall-effect sensor is directly mounted to the circuit board and the circuit board is shaped to bring the sensor immediately adjacent to a moving component to be monitored
Implementation Method 2
the moving component to be monitored is provided with a magnet that produces a magnetic field sensed by the reed switch or Hall-effect sensor
Data Source
AI summary
A locking device includes an integrated circuit board specially shaped to fit the locking device and to bring a sensor on the circuit board adjacent to a moving lock component. The circuit board is preferably routed to form a convex shape that matches the locking device and provides printed circuit wiring to connect one or more sensors or other components to an external wiring harness, thereby reducing point-to-point wiring within the lock. Multiple different circuits may be provided on the same circuit board, which are automatically selected by the connectors used on different corresponding wiring harnesses and/or actuators. The design reduces assembly costs and allows rapid electrification of existing mechanical locking devices with minimal modification.