Universal Holder for Physical Quantity Sensor Assembly

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Solution Overview

Problem

Existing physical quantity measuring devices require different manufacturing processes depending on their intended use, limiting the common use of components across various applications, particularly in clean room environments where ultrasonic cleaning is necessary to remove welded spatters.

Innovation Solution

A physical quantity measuring device design featuring a holder with engaging projections that can be attached to either a connector or a cover, allowing for common use of components across different manufacturing processes, with the holder maintaining consistent distance between the electronic circuit and sensor module in both postures, enabling easy adjustment and preventing water ingress through operation holes covered by cap members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the case is welded to the joint after the circuit substrate is attached to the joint, then the manufacturing process is simplified, but ultrasonic cleaning cannot be applied to the welded portion

Engineering Contradiction:

Improvemanufacturing process simplificationVSAvoidcleaning capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The device is divided into two separate assembly sequences: one where the circuit substrate is attached before welding (allowing post-weld cleaning), and another where the cover is attached after welding. This segmentation allows each configuration to be optimized for its specific cleaning requirements while using the same holder component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holder is designed as a universal component that can be used in both manufacturing configurations. It features engaging projections that can connect to either the connector or the cover, making it adaptable to different assembly sequences and cleaning requirements without needing separate support members.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If different support members are used for different manufacturing processes, then each process can be optimized, but component commonality is reduced

Engineering Contradiction:

Improveprocess optimizationVSAvoidcomponent commonality

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The holder's functionality is made dynamic through its engaging projections that can selectively connect to different components (connector or cover) depending on the manufacturing process being used. This dynamic adaptability allows a single component to serve multiple purposes across different assembly sequences.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If the circuit substrate is exposed during welding, then assembly is simplified, but welded spatters may contaminate the circuit substrate

Engineering Contradiction:

Improveassembly simplicityVSAvoidwelded spatter contamination

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The cover acts as an intermediary protective element that can be attached to the cylindrical case before welding. This shields the circuit substrate (held by the holder) from welded spatter contamination while still allowing the welding process to proceed. The cover can be removed or designed to allow ultrasonic cleaning of the welded portions.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables the use of common components across different manufacturing processes, facilitates easy adjustment of the electronic circuit, prevents water ingress, and allows for ultrasonic cleaning of welded portions without affecting the circuit substrate, enhancing manufacturing flexibility and device reliability.

Implementation Method 1

the holder includes, at the first end, an engaging projection engaged with a first engagement groove provided to the connector when the holder is in the first posture

Methodology Applied

Scientific EffectMechanical Fastener: Mechanical Fastener

Implementation Method 2

the welded portion is occasionally subjected to ultrasonic cleaning in a manufacturing process

Methodology Applied

Scientific EffectUltrasonic cleaning: Ultrasonic Vibration

Implementation Method 3

preventing water ingress through operation holes covered by cap members

Methodology Applied

Scientific EffectPhysical Containment: Physical Containment

Data Source

PatentUS11085847B2Physical quantity measuring device and manufacturing method of physical quantity measuring device

Publication Date: 2021.08.10 NAGANO KEIKI

AI summary

A physical quantity measuring device includes a sensor module; a joint attached with the sensor module; a connector configured to be connected to a first or a second cylindrical case and the joint; a circuit substrate attached with an electronic circuit configured to receive a signal detected by the sensor module; and a holder holding the circuit substrate. The holder can be housed in the first cylindrical case in a first posture where a first end is engaged with a first connector and a second end is in contact with a first cover, or in a second cylindrical case in a second posture where the first end is engaged with a second cover and the second end is in contact with a second connector. The holder has an engaging projection engageable with a first engagement groove provided to the first connector and a second engagement groove provided to the second cover.