Spring-Based Electrical Connection for Sensor Housing
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Solution Overview
Problem
Existing sensors face challenges in maintaining secure and permanent electrical connections under varying environmental conditions, particularly in harsh measurement settings, where external influences can damage components and disrupt functionality.
Innovation Solution
The use of springs as contact elements extending from the housing to form electrical connections with external devices, allowing for secure and adaptable contact through mechanical and electrical means, including compressive loading and preloading, and utilizing conductive materials with low resistance and corrosion resistance for reliable signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a socket with pins is used for electrical connection, then the connection is compatible with external devices, but the connection may become loose or damaged under varying environmental conditions
Solution Approach 1:
The spring element is designed to be dynamically adaptable, automatically adjusting its contact pressure in response to environmental variations such as temperature changes, mechanical stress, or misalignment. This dynamic behavior ensures continuous reliable electrical contact without requiring precise pre-adjustment, resolving the contradiction between connection reliability and environmental adaptability.
Solution Approach 2:
The spring element changes its physical parameters (contact force, position) in response to environmental conditions. The spring constant, preload force, and contact pressure are designed to vary within acceptable ranges to maintain reliable electrical connection across different environmental scenarios, thus adapting to conditions while preserving connection integrity.
2Reliability
If the spring is pre-tensioned to establish electrical contact, then reliable contact is achieved, but the spring may exert excessive force on the housing or connector
Solution Approach 1:
The spring element is pre-tensioned to establish initial contact force before the sensor is fully installed or before environmental variations occur. This beforehand cushioning ensures that the electrical contact is already established and maintained, compensating for potential gaps or misalignments without requiring excessive ongoing force on the housing or connector.
Solution Approach 2:
The spring acts as an intermediary element between the housing and the electrical connector, mediating the force transmission. It provides the necessary contact force for reliable electrical connection while distributing and limiting the force applied to the housing and connector, preventing damage while ensuring contact reliability.
3Ease of operation
If the spring extends through the housing wall, then external electrical connection is achieved, but the spring may be exposed to environmental factors that could damage it
Solution Approach 1:
The spring element is designed with a flexible, corrosion-resistant structure that can withstand environmental exposure. The spring material and surface treatment provide protection against corrosion and degradation from environmental factors such as moisture, chemicals, or temperature extremes, while maintaining the flexibility needed for electrical connection 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 solution ensures reliable, reproducible, and adaptable electrical contact, even in difficult-to-access areas, protecting sensor components from environmental factors while maintaining signal integrity and ease of connection.
Implementation Method 1
a spring, or several springs (18), which extend from a contact surface (17) inside the housing (2) through the housing wall (21) to the outside and form an outer contact surface (16)
Implementation Method 2
a structural element that can absorb work over a relatively large distance and store this energy, either wholly or partially, as deformation energy, in order to release it again
Implementation Method 3
The spring can be completely or at least partially coated with materials that exhibit low electrical resistance and low corrosion
Data Source
Figure 1~2
AI summary
The invention relates to a sensor for detecting a physical or chemical property from the environment, which has at least the following components: a measuring transducer 7, a device for generating a measuring signal and its transmission, a housing 2 for protecting at least one of the aforementioned components, and at least one external electrical connection 15 for outputting an electrical measuring signal.To make the electrical connection 15 compatible with various external devices, it is formed by a spring 18 in conjunction with a contact surface inside the housing 2, hereinafter referred to as the inner contact surface 17, wherein the spring 18 extends from the inner contact surface 17 through the housing wall and forms an outer contact surface 16 outside the housing 2, whereby an electrically conductive path between the inner contact surface 17 and the outer contact surface 16 can be established by means of the spring 18. (Fig. 1).