Integrally Formed Wire Contact Element for Sensor Assembly
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Solution Overview
Problem
The complex and costly manufacturing process of connecting sensors to printed circuit boards due to narrow installation spaces and the need for decoupling of process steps in existing technologies, which complicates the formation of electrical contact connections using thin Cu wires.
Innovation Solution
A contact element with a wire-like projection integrally formed from strip or sheet material, allowing for simplified electrical contact connection without the need for additional connecting points, using techniques like stamping or laser processing, and enabling mechanical decoupling and damping of acoustic oscillations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thin Cu wires are used to establish electrical contact connection between contact element and piezo oscillator, then electrical contact is achieved, but the manufacturing process becomes complex and costly due to multiple process steps
Solution Approach 1:
The patent combines the contact element main body and the contact wire into a single integrally formed component made of strip or sheet material. This merging eliminates the need for separate wire attachment processes (soldering, welding, or bonding) and reduces the number of manufacturing steps while maintaining reliable electrical contact connection.
Solution Approach 2:
The strip or sheet material serves multiple functions simultaneously: it forms the structural main body of the contact element, provides the contact wire for electrical connection, and enables both mechanical and acoustic decoupling through its geometric design. This multi-functionality reduces the need for additional components and process steps.
2Reliability
If Cu wire is used for electrical contact, then connection is established, but additional process steps (soldering, welding, bonding) are required increasing manufacturing complexity
Solution Approach 1:
The contact wire and main body are merged into a single integrally formed component from strip or sheet material, eliminating the need for separate joining processes such as soldering, welding, or bonding. This significantly simplifies the manufacturing process while ensuring reliable electrical contact.
Solution Approach 2:
The contact wire geometry is pre-formed as part of the main body during the stamping or laser cutting process, rather than being attached later. This preliminary formation of the contact structure eliminates subsequent joining steps and reduces manufacturing complexity.
3Ease of operation
If contact elements are positioned and wired outside sensor housing, then assembly is possible, but narrow installation space conditions complicate the process
Solution Approach 1:
The contact element is designed with integrated segmentation where the main body and contact wire are formed as one piece with distinct functional zones. This allows the component to be assembled in a single step without requiring separate positioning and wiring operations within the constrained housing space.
Solution Approach 2:
By merging the contact wire and main body into a single integrally formed component, the assembly process is simplified to a single insertion operation, eliminating the need for separate wire positioning and attachment steps within the narrow installation space of the sensor housing.
4Reliability
If multiple process steps are used for contact connection, then electrical contact is achieved, but process control becomes complicated and expensive
Solution Approach 1:
The manufacturing process is merged into a single stamping or laser cutting operation that forms both the main body and contact wire geometry simultaneously. This eliminates multiple process steps and their associated control requirements, reducing both complexity and cost while maintaining connection reliability.
Solution Approach 2:
The contact wire geometry is preliminarily formed as part of the main body during the initial stamping or laser cutting process. This preliminary formation eliminates the need for subsequent wiring and attachment processes, significantly simplifying process control.
Data Source
AI summary
A contact element (30′), including a base body made of a strip material and/or sheet material, and at least one contact segment (30.1, 30.2′) which is connected to the base body and which is designed to make electric contact between the contact element (30′) and a contact partner, in particular an electric and/or electronic component. The at least one contact segment (30.2′) is embodied as a wire-like extension, which is formed integrally with the base body from the strip and/or sheet material. In addition, at least one end of the wire-like extension forms a transition region (31), which adjoins the base.