Split Electronic Module Case for Sensor Substrate Assembly
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Solution Overview
Problem
Existing electronic modules with boat-shaped cases face limitations in manufacturing due to restricted substrate positioning and directional constraints, leading to increased costs and reduced efficiency in electrical connections and mounting flexibility.
Innovation Solution
An electronic module design featuring a body case with multiple interlocking members and dual openings allows for high positioning accuracy and flexibility in substrate orientation, using a resin body to integrate the case members and substrate, enabling easy electrical connections and varied mounting configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a boat-shaped case with a single opening is used to house the substrate, then the case can be manufactured by resin molding at low cost, but the substrate positioning and electrical connection become restricted and complex
Solution Approach 1:
The case is divided into multiple members (first case member and second case member) that can be separated from each other. This segmentation allows the substrate to be inserted from the side through the gap between members, eliminating the need for complex internal positioning structures and simplifying electrical connections while maintaining low-cost resin molding manufacturing.
2Ease of manufacture
If the metal pin is arranged standing from the bottom wall to reduce cost, then the electrical connection is simplified, but the substrate housing shape becomes limited and soldering operation efficiency decreases
Solution Approach 1:
Instead of arranging the metal pin vertically from the bottom wall, the pin is positioned horizontally on the side surface of the case member. This dimensional change allows the substrate to be inserted from the side with the pin exposed, enabling soldering operations to be performed from the side rather than through the top opening, thereby improving operation efficiency while maintaining cost-effectiveness.
3Manufacturing precision
If the case members are made separable to provide wide opening for substrate insertion, then positioning accuracy and mounting ease are improved, but the case structure becomes more complex
Solution Approach 1:
The first case member and second case member are designed to be separable, creating a wide opening for substrate insertion. The members are coupled together through simple coupling structures (such as protrusions and recesses) that provide precise positioning alignment. This merging of multiple members with simple coupling mechanisms achieves high positioning accuracy without significantly increasing overall structural complexity.
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 design enhances waterproofing, strength, and manufacturing efficiency, allowing for cost-effective production of modules with diverse specifications and improved assembly processes.
Implementation Method 1
a resin body that covers the substrate by being filled into the internal space of the body case and solidified or hardened
Data Source
AI summary
The Electronic Module includes body case 2 that comprises a plurality of case members 3, 4 by abutting each other and that has an internal space (S) where the first opening P1 is formed on one side surface of the internal space (S) and the second opening P2 that opens in a direction different from that of the first opening P1 is in an exposed state when a plurality of the case members 3, 4 are separated each other, a substrate 5 on which a sensor IC 51 is mounted and that is housed in the internal space (S) of the body case 2, and a resin body 6 that covers the substrate 5 by being filled in the internal space (S) of the body case 2 and solidified or hardened, and is characterized by that a plurality of the case members 3, 4.