Water-in-fuel sensor board-mounting subassembly
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Solution Overview
Problem
Existing water-in-fuel sensor assemblies for engine systems are cumbersome to assemble due to the process of coupling a circuit board to pins, requiring a more cost-effective and easy-to-assemble solution.
Innovation Solution
A water-in-fuel sensor assembly with a board-mounting subassembly that includes a circuit board, terminals, and resistors, which are collectively engaged with pins within a housing recess, allowing for easy installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate circuit board housing is used to couple the circuit board to the pins, then the electrical connection is reliable, but the assembly process becomes cumbersome and complex
Solution Approach 1:
The patent merges the circuit board housing, circuit board, and terminal coupling mechanisms into a single integrated board-mounting subassembly. This subassembly is designed as one collective body that can be easily installed or removed from the sensor housing, eliminating the need for separate coupling operations and reducing assembly complexity while maintaining reliable electrical connections.
2Ease of manufacture
If traditional separate component assembly is used, then each component can be optimized independently, but the overall assembly process is time-consuming and labor-intensive
Solution Approach 1:
The patent applies preliminary action by pre-assembling the circuit board, terminals, and housing into an integrated board-mounting subassembly before final installation. This subassembly is prepared in advance with all necessary electrical connections and mechanical structures already in place, allowing for rapid installation into the sensor housing and significantly reducing assembly time and labor requirements.
3Adaptability or versatility
If multiple separate parts are used for the circuit board mounting, then the design is flexible, but the assembly requires more steps and is more difficult to manufacture
Solution Approach 1:
The patent combines the circuit board, terminals, and mounting structure into a single integrated subassembly that maintains design flexibility while simplifying manufacturing. The subassembly is designed as one collective body with standardized interfaces, allowing for easy adaptation to different sensor configurations while reducing the number of manufacturing steps and assembly operations required.
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
The board-mounting subassembly simplifies the assembly process by combining components into a single entity that can be easily installed or removed, eliminating the need for a separate circuit-board housing and reducing assembly complexity.
Implementation Method 1
at least one terminal coupled to the circuit board. The at least one terminal is engaged with the at least one pin
Data Source
AI summary
A method of assembling a water-in-fuel sensor assembly. The method includes an initial step of providing a housing that has a recess, at least one pin located within the housing, a circuit board, and at least one terminal configured for engaging the at least one pin. The method also includes forming a board-mounting subassembly by coupling the at least one terminal to the circuit board. The method also includes positioning the board-mounting subassembly within the housing by engaging the at least one terminal with the at least one pin such that the board-mounting subassembly is disposed within the recess of the housing.