Sensor device with crimp housing and assembly method thereof

Abstract

A sensor device having a crimped housing and a method for assembling a sensor device having a crimped housing are disclosed. The sensor device includes: a sensor port; a tubular thin-walled housing coupled to the sensor port and including a crimping portion, a base portion, and a stepped feature formed in the housing, the stepped feature separating the crimping portion from the base portion; a sensor component disposed within the base portion of the housing; and an electrical connector coupled to the housing and including a lead electrically coupled to the sensor component and a connector flange, wherein an edge of the crimping portion of the housing is crimped onto the connector flange so that the electrical connector is retained in the housing. The recesses created by the protrusions on the crimping die on the housing edge and the connector flange ensure that the housing edge secures the connector in a rotational direction.

Description

Background Art

[0001] The sensor device can be used to measure environmental conditions. For example, the pressure sensor device can be used in industrial applications to monitor pressure conditions and transmit them electrically to a remote location via a wired link or a wireless connection. One type of pressure sensor device includes multiple components. For example, the pressure sensor device can include a metal base component and a housing that houses the pressure sensor electronics and a sensing element. The pressure sensor electronics in the pressure sensor device can be configured to receive a signal from a sensing element (e.g., a capacitive sensing element, a resistive sensing element, etc.). The sensing element can detect the pressure of a fluid received through a channel of the metal base component. The signal transmitted from the sensing element to the pressure sensor electronics varies depending on the pressure of the sensed fluid. In addition to the metal base component, the pressure sensor device can also include a connector component electrically coupled to the pressure sensor electronics.

[0002] During assembly of the pressure sensor assembly, after the pressure sensor electronics, the connector component, and a portion of the connector assembly are inserted into the housing, a portion of the housing can be crimped onto the portion of the connector assembly in the housing to prevent the connector component from being removed from the pressure sensor assembly. After crimping, the connector component securely holds the pressure sensor electronics in the housing.

[0003] During operation, the pressure sensor electronics in the device housing generate a signal indicative of the sensed pressure. The pressure sensor electronics transmit the pressure information to a remote location via wires in the connector assembly. Summary of the invention

[0004] Embodiments according to the present invention relate to a sensor device having a crimp housing and a method for assembling a sensor device having a crimp housing.

[0005] According to one embodiment of the present invention, there is a sensor device. The sensor device includes a sensor port and a tubular thin-walled housing coupled to the sensor port. The tubular housing includes a crimping portion, a base portion, and a stepped feature formed in the housing. The stepped feature separates the crimping portion from the base portion. In this embodiment, the sensor component is disposed within the base portion of the housing. An electrical connector is coupled to the housing and includes a lead and a connector flange electrically coupled to the sensor component. The edge of the crimping portion of the housing is crimped onto the connector flange, thereby securing the electrical connector in place.

[0006] The sensor component may include a sensing element, an electronic circuit electrically coupled to the sensing element, and a flexible printed circuit board electrically coupled to the electronic circuit. The leads of the connector may contact the flexible printed circuit board. The sensor device may also include a sealant in a joint between the electrical connector and the crimping portion of the housing. The housing of the sensor device may be welded to the sensor port.

[0007] According to the principles of the present invention, the housing can be formed by a stamping process. In some embodiments, the thickness of the housing wall in the base portion and the thickness of the housing wall in the crimping portion of the housing vary according to the direction of the stamping process. When the direction of the stamping process is a first direction, the thickness of the housing wall in the base portion exceeds the thickness of the housing wall in the crimping portion. When the direction of the stamping process is a second direction, the thickness of the housing wall in the crimping portion exceeds the thickness of the housing wall in the base portion. The stepped feature of the housing can be an annular ledge that supports the flange during the crimping process of the crimping portion. Alternatively, the stepped feature can be a plurality of protrusions formed on the inner surface of the housing corresponding to a plurality of grooves in the flange of the electrical connector.

[0008] The sensor device may be a pressure sensor device, wherein the sensor component may include a sensing element for measuring fluid pressure and a pressure sensor circuit coupled to the sensing element to convert the pressure sensed by the sensing element into an electronic signal. The port may include a channel for introducing the fluid into the sensing element.

[0009] Another embodiment according to the present invention relates to a method for assembling a sensor device having a crimped housing. The method includes receiving a tubular housing on a sensor port. The housing includes a crimping portion, a base portion, and a stepped feature formed in the housing. The stepped feature separates the crimping portion from the base portion. The method also includes disposing a sensor component in the housing and inserting at least a portion of an electrical connector into the housing, including disposing an annular flange of the electrical connector in the crimping portion of the housing so that the bottom surface of the flange contacts the stepped feature. The method also includes placing a support die (dye) around the base portion of the housing and crimping the crimping portion of the housing onto the flange so that the edge of the crimping portion bends onto the top surface of the flange.

[0010] Crimping the crimping portion of the housing onto the flange so that the edge of the crimping portion is bent to contact the top surface of the flange may include, by a first crimping die, bending the edge of the crimping portion inwardly toward the rotation axis of the housing so that the edge overhangs or contacts the top surface of the flange. In some embodiments, the first crimping die includes die protrusions that form one or more dimples in the edge of the crimping portion during the crimping process and corresponding dimples in the flange of the connector, thereby inhibiting the rotation of the connector in the housing. Crimping the crimping portion of the housing may also include, by one or more second crimping dies, bending the edge of the edge toward the top surface of the flange so that the inner wall of the edge contacts the top surface of the flange. The first crimping die may include a curved lip and a radial constraint portion. In this embodiment, when the first crimping die approaches the support die during the crimping process, the crimping portion may deform according to the curvature of the lip, while the radial constraint portion prevents the crimping portion from bulging. The one or more second crimping dies may include a flat end for pushing the edge of the crimping portion against the top surface of the flange after the edge of the crimping portion is bent by the first crimping die. In one embodiment, the bending performed by the second crimping die includes retaining the first crimping die in an appropriate position so that the radial constraint of the first crimping die prevents the crimping portion from protruding. In another embodiment, the bending performed by the second crimping die includes not retaining the first crimping die in an appropriate position, wherein the protrusion of the crimping portion is provided by the radial constraint of the second crimping die.

[0011] The method may further include sealing a joint between the crimping portion and the electrical connector with a sealant after crimping. The method may further include welding the housing to the sensor port before receiving the housing and the sensor port or after crimping.

[0012] According to the principles of the present invention, the shell can be formed by a stamping process. In some embodiments, the thickness of the shell wall in the base portion and the thickness of the shell wall in the crimping portion of the shell vary according to the direction of the stamping process. When the direction of the stamping process is a first direction, the thickness of the shell wall in the base portion exceeds the thickness of the shell wall in the crimping portion. When the direction of the stamping process is a second direction, the thickness of the shell wall in the crimping portion exceeds the thickness of the shell wall in the base portion. The stepped feature portion of the shell can be an annular boss that supports the flange during the crimping process of the crimping portion. Alternatively, the stepped feature portion can be a plurality of protrusions formed on the inner surface of the shell corresponding to a plurality of grooves in the flange of the electrical connector.

[0013] The assembled sensor device can be a pressure sensor device, and the sensor component includes at least a sensing element for measuring fluid pressure and a pressure sensor circuit coupled to the sensing element to convert the pressure sensed by the sensing element into an electronic signal. The port can include a channel for introducing the fluid into the sensing element.

[0014] The foregoing and other objects, features, and advantages of the present invention will become apparent from the following more particular description of exemplary embodiments of the present invention as illustrated in the accompanying drawings wherein like reference numerals generally represent like parts of exemplary embodiments of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a diagram showing an isometric view of an assembled sensor device according to an embodiment of the present invention;

[0016] Figure 2 It is shown Figure 1 An illustration of an isometric view of a sensor device prior to assembly;

[0017] Figure 3 is a diagram showing an isometric view of a particular embodiment of a sensor device housing according to an embodiment of the present invention;

[0018] Figure 4 is a diagram showing a partial cross-sectional view of a sensor device according to an embodiment of the present invention before crimping;

[0019] Figure 5 is a diagram showing a partial cross-sectional view of a sensor device according to an embodiment of the present invention after crimping;

[0020] Figure 6 is a diagram showing a partial cross-sectional view of an apparatus for crimping a sensor device housing according to an embodiment of the present invention;

[0021] Figure 7 is a diagram showing a partial cross-sectional view of an apparatus for crimping a sensor device housing according to an embodiment of the present invention;

[0022] Figure 8 is a diagram showing a partial cross-sectional view of an apparatus for crimping a sensor device housing according to an embodiment of the present invention;

[0023] Fig. 9 is a diagram showing an exemplary crimping die according to an embodiment of the present invention;

[0024] Fig.10is a diagram showing another exemplary crimping die according to an embodiment of the present invention;

[0025] Fig.11 is a diagram showing a perspective view of another exemplary sensor device housing according to an embodiment of the present invention;

[0026] Fig.12 is a diagram showing a top view of a connector according to an embodiment of the present invention;

[0027] Fig.13 is a flow chart illustrating a specific embodiment of a method of assembling a sensor device having a crimp housing according to an embodiment of the present invention;

[0028] Fig.14 is a flow chart illustrating another embodiment of a method of assembling a sensor device having a crimp housing according to an embodiment of the present invention;

[0029] Fig.15 is a diagram showing a partial cross-sectional view of an apparatus for crimping a sensor device housing according to an embodiment of the present invention;

[0030] Fig.16 is a diagram showing a partial cross-sectional view of an apparatus for crimping a sensor device housing according to an embodiment of the present invention;

[0031] Fig.17 is a diagram showing a partial cross-sectional view of a device for crimping a sensor device housing according to an embodiment of the present invention; and

[0032] Fig.18 is a diagram showing a perspective view of another exemplary sensor device housing according to an embodiment of the present invention. DETAILED DESCRIPTION

[0033] Crimping machines are used to form a strong connection between metal and plastic parts. For example, for pressure sensors, this crimping process is commonly used to crimp tubular housings around the flanges of plastic electrical connectors. These housings are typically machined housings and typically have a strong base at the bottom and a weak, thin-walled area at the top so that they can be properly crimped around the top without buckling the bottom area. Current crimping processes do not allow for crimping of tubular housings with constant wall thickness because the bottom area is as susceptible to deformation as the top area due to the equal stiffness of the two areas. When considering the deep drawing manufacturing process, the tubular housing can be made very thin, which is much less expensive than machining processes due to low material loss and high productivity. Therefore, the present invention is directed to the use of a crimping process that allows housings with constant wall thickness to be crimped without buckling the non-crimped base area of ​​the housing.

[0034] Embodiments according to the present invention relate to a sensor device having a crimped housing and a method for crimping a housing of a sensor device, wherein the benefits of a thin-walled stamped housing are achieved. For example, in one embodiment, a tubular housing is welded to a sensor port. The housing includes a crimping region, a base region, and a stepped feature formed in the housing. The stepped feature effectively separates the crimping portion from the base portion. However, the wall thickness of the housing in the crimping region and the base region is generally equal, and there may be thickness variations in certain local areas. According to various known methods that those skilled in the art will recognize, the sensor component is arranged in the cavity of the tubular housing. At least a portion of the electrical connector is inserted into the housing. The portion included in the housing includes an annular flange, which is arranged in the crimping region of the housing so that the bottom surface of the flange contacts the stepped feature. A support die can be placed around the base region of the housing to prevent buckling. Then, the crimping region of the housing is crimped on the flange so that the edge of the crimping region is bent onto the top surface of the flange.

[0035] In some embodiments, crimping is performed by a single crimping die. However, in order to reduce the amount of air between the edge and the flange of the housing, two crimping dies can be used. In the crimping process of this embodiment, the first crimping die bends the edge of the crimping portion inwardly toward the axis of rotation of the housing so that the edge overhangs or contacts the top surface of the flange. The first crimping die may include a die protrusion that forms one or more pits in the edge of the crimping portion and forms corresponding pits in the flange of the connector during the crimping process, thereby inhibiting the rotation of the connector in the housing. The second crimping die bends the edge of the edge toward the top surface of the flange so that the inner wall of the edge contacts the top surface of the flange. The first crimping die includes a curved lip, wherein when the first crimping die approaches the supporting die during the crimping process, the crimping portion is deformed according to the curvature of the lip. The first crimping die also includes a radial constraint portion that prevents the crimping portion from protruding outward during the crimping process. The second crimping die includes a flat end for pushing the edge of the crimping portion against the top surface of the flange after the edge of the crimping portion is bent by the first crimping die. The second crimping die may also include a radial constraint portion that prevents the crimping portion from protruding outward during the crimping process. In one embodiment, after crimping, the joint between the crimping portion and the electrical connector, that is, the area between the edge of the edge and the top surface of the connector flange, is sealed with a sealant.

[0036] As previously described, the housing can be a stamped metal housing, which is less expensive to produce than a machined housing. The housing includes a stepped feature, i.e., one or more protrusions on the inner wall of the tubular housing. For example, the protrusion can be an annular boss. As another embodiment, the protrusion can be a plurality of protrusions on the inner circumference of the housing, which are located in the same plane orthogonal to the rotation axis of the housing. The stepped feature is formed near the plane of the housing of the connector, effectively dividing the housing into two regions, so that the crimping area is smaller than the base area.

[0037] Another embodiment relates to a sensor device constructed using the above process. For example, the sensor includes a sensor port and a tubular housing, the tubular housing is coupled to the sensor port and includes a crimping area, a base area, and a stepped feature formed in the housing, the stepped feature separating the crimping area from the base area. The sensor includes a sensor component disposed in the base area of ​​the housing. An electrical connector is coupled to the housing and includes leads electrically coupled to the sensor component. The connector includes a flange, and the edge of the crimping area of ​​the housing is crimped on the connector flange so that the electrical connector is retained in the housing. The sensor component includes a sensing element, an electronic circuit electrically coupled to the sensing element, and may include a flexible printed circuit board electrically coupled to the electronic circuit or a flexible wire with a connector to the electronic circuit at one end. The leads of the connector may be connected to the other end of the flexible wire, or may be electrically coupled to the flexible printed circuit board by contact with the printed circuit board or by welding the wire and / or the wire with the connector to the printed circuit board. The flexible printed circuit board allows for a modular design of the sensor device, so that different types of connectors can be coupled to the electronic sensor circuit by selecting a corresponding configuration of the flexible printed circuit board. Different types of flexible printed circuit boards have different configurations that correspond to the lead configurations of the connectors, but each flexible printed circuit board can use the same configuration to interface with the electronic sensor circuitry. After crimping the housing, a sealant can be used around the joint between the connector flange and the crimp area to further protect the internal sensor components from external elements.

[0038] In one embodiment, the sensor is a pressure sensor. The sensor component includes at least a sensing element for measuring fluid pressure and a pressure sensor circuit coupled to the sensing element to convert the pressure sensed by the sensing element into an electronic signal, and the port includes a channel for introducing the fluid into the sensing element. The electrical connector includes leads that electrically connect the sensor circuit inside the housing to an external device, for example, through a cable.

[0039] As previously described, the housing of the sensor device can be a stamped metal housing, which has a lower production cost than a machined housing. The housing includes a stepped feature, i.e., one or more protrusions on the inner wall of the tubular housing. For example, the protrusion can be an annular boss. As another embodiment, the protrusion can be a plurality of protrusions on the inner circumference of the housing, which are located on the same plane orthogonal to the axis of rotation of the housing. The stepped feature is formed at the plane of the housing near the connector, effectively dividing the housing into two regions, so that the crimping area is smaller than the base area. In a specific embodiment, the wall thickness of the crimping area and the wall thickness of the base area may be substantially equal to the thickness variation of the local area.

[0040] The advantages and other features of the systems and methods disclosed herein will be more readily understood by those of ordinary skill in the art through the following detailed description of certain preferred embodiments in conjunction with the accompanying drawings that illustrate representative embodiments of the invention. The same reference numerals are used herein to represent the same parts. In addition, words that define orientation, such as "upper", "lower", "far" and "near" are only used to help describe the position of components relative to each other. For example, the "upper" surface of a part is only used to describe a surface that is separated from the "lower" surface of the part. Words indicating orientation are not used to describe an absolute orientation (i.e., the "upper" part must always be at the top).

[0041] Figure 1 is an illustration showing an isometric view of an assembled sensor device (100) having a crimped housing according to the present invention. As a non-limiting embodiment, the device (100) can be a pressure sensor well suited for industrial or automotive applications, or heating, ventilation and air conditioning (HVAC) systems. For example, the device (100) can be used to detect coolant pressure, oil or fuel pressure, hydraulic pressure, and other fluid and gas pressures. As other non-limiting embodiments, the device (100) can be a pressure switch, a temperature sensor, a combined temperature and pressure sensor, and other sensors that will occur to those skilled in the art. Figure 1 The device (100) includes a connector (110) coupled to a thin-walled tubular housing (hereinafter referred to as "housing") (130). In a specific embodiment, the housing (130) can be a metal housing with a wall thickness between 0.2 mm and 2.0 mm. Figure 1 In the embodiment of the present invention, the housing (130) is located on the port (170). For example, the connector (100) can be an electrical connector for connecting an external component to an electrical component contained in the housing (130), which will be explained in the following description. The port (170) can be a connector (e.g., a mechanical pressure connector) that can be connected to a fluid channel and expose the sensor component in the housing (130) to a liquid or gas, which will be explained in the following description.

[0042] Figure 2 It is shown Figure 1 1 is an illustration of an isometric view of the sensor device (100) prior to assembly. The connector (110) can be, for example, an electrical connector in accordance with known electrical connector packaging and interfaces. Examples of such electrical connectors include, but are not limited to, M12 type connectors, Metri-Pack type connectors, any DIN standard type connectors, Deutsch standard type connectors, or flying lead type connectors, as well as other such connectors that will be recognized by those skilled in the art. One or more electrical leads (118) (see Figure 5 ) transmits electrical signals from electrical components within the housing (130) to external components. The connector (110) includes a connector flange (112) located within the housing (130). The connector flange (112) provides support around which the housing (130) can be crimped, as will be described in further detail herein.

[0043] The housing (130) may be a stamped metal housing having a crimping portion (131) and a base portion (133) separated by a stepped feature (132), the stepped feature (132) being used to seat the connector (110) in the housing (130) and crimp the crimping portion (131) of the housing (130) to the connector (110). The housing (130) may be further coupled to the port (170) by, for example, welding or crimping a bottom edge (134) of the base portion (133) of the housing (130) to the port (170). The cavity (135) of the housing (130) surrounds the flexible circuit board (140), the circuit module (150), and the sensing element device (160). In some embodiments, a seal (120) may be applied to the connector (110) and the housing (130) to hermetically seal the cavity (135).

[0044] The flexible circuit board (140) can be connected to the lead wire (118) of the connector (110) (see Figure 5) is configured according to the pin configuration of the connector (110). That is, the electrical contacts (141) in the flexible circuit board (140) are configured to receive the electrical leads (118) of the connector (110). The flexible circuit board (140) includes a cable (142) for connecting to the circuit module (150). The flexible circuit board (140) receives electrical signals from the circuit module (150) via the cable (142) and relays these signals to the electrical leads (118) of the connector (110). Therefore, a flexible circuit board (140) corresponding to the type of connector (110) can be used to adapt the connector (110) to the circuit module (150) without configuring the circuit module (150) for a specific type of connector. In some embodiments, the flexible circuit board (140) can be replaced by a flexible wire (not shown) having one end connected to the electrical leads (118) and the other end connected to the circuit module (150). The flexible wires (not shown) may be connected to the electrical leads (118) and the circuit module (150) by connectors, welding, or any other electrical connection method that would occur to one skilled in the art.

[0045] The circuit module (150) includes a circuit (151) configured to process, transmit and / or store signals from the sensing element (160). For example, this circuit can be an application specific integrated circuit (ASIC) configured to convert the signals from the sensing element (160) into data understandable by an external component. The circuit module (150) can include a base (152) that supports the circuit (151) within the housing (130). The base (152) can be placed on the port (170).

[0046] The sensing element device (160) is configured to sense the axial passage (171) of the port (170) (see Figure 5 ) and may have a lower surface exposed to the fluid in the axial channel (171) of the port (170), or may be offset from the center relative to the axial channel (171). For example, the sensing element device (160) may include a capacitive sensing element, a resistive sensing element, etc. designed to measure the bending of the diaphragm. The bottom of the sensing element device (160) and the joint of the port (170) may be sealed to prevent the fluid in the axial channel (171) from flowing into the cavity (135) of the housing (130). The sensing element device (160) is coupled to the circuit module (150), and the circuit module (150) processes, transmits and / or stores signals from the sensing element (160).

[0047] The port (170) can be, for example, a pressure connector according to a well-known pressure connector interface and thread size. Examples of such pressure connectors include G1 / 4ADIN3852-E, 7-16 / 20UNF, NPT1 / 4 or PT1 / 4 pressure ports, and other such connectors that will be recognized by those skilled in the art. As another embodiment, the port (17) can be a temperature sensor port. The port (170) includes a port connector (175) that can be inserted into a fluid channel for detecting, for example, the pressure or temperature of the fluid in the channel. The port connector (175) of the port (170) can introduce the fluid from the fluid channel to the sensing element device (160) through an axial channel (171) in the port (170). The port (170) can be made of any suitable material (such as brass, copper, alloy, moldable plastic, etc.). In one embodiment, the port (170) is milled from a metal such as brass, aluminum, copper, stainless steel, etc. Port (170) may include a hexagonal flange (173) or other suitable pattern to enable application of torque.

[0048] To further illustrate, Figure 3 An enlarged view of the housing (130) is shown. The housing (130) may be cylindrical, tubular, or other suitable shapes with an open cavity (135). The housing (130) includes a crimping portion (131), which is a deformable portion of the housing that is suitable for bending and crimping. The crimping portion (131) includes a crimping portion (see Figure 4 ) during the process of contacting the connector flange (112). The housing (130) also includes a base portion (133) in which the sensor component is housed. The housing (130) also includes a stepped feature (132), which can be, for example, an annular boss or a plurality of protrusions. Figure 3In the illustrated embodiment, the stepped feature (132) is shown as an annular boss. The stepped feature (132) provides support to keep the connector flange (112) against the crimping process and also prevents the connector (110) from being pushed into the housing (130). The stepped feature (132) also provides bending and torsional stiffness to the thin-walled housing, thereby enhancing load absorption in all six degrees of freedom. For example, the stepped feature (132) can be an annular boss that acts as a spring to absorb axial loads and axially preload the housing (130) to provide a higher friction torque when torque is applied to the connector (110). When the connector (110) is made of plastic, the connector (110) will creep (relax) due to the crimping force. The spring preload function will better maintain the service life of the connector (110), thereby giving it a higher anti-rotation torque. The housing (130) can be formed from metal by a stamping process. The stepped feature (132) can be formed on the inner wall of the housing (130) based on any suitable metalworking operation. The housing (130) can be coupled to the port by, for example, welding or crimping the bottom edge (134) of the base portion (133) of the housing (130) to the port.

[0049] To further illustrate, Figure 4 1 shows a cross-sectional view of the housing (130) and the connector (110) prior to crimping. Figure 4As shown, the connector flange (112) is disposed in a cavity (135) within the crimping portion (131) of the housing (130). The top surface (113) of the connector flange is located below the upper edge (137) of the crimping portion (131) of the housing (130). The bottom surface (115) of the connector flange (112) contacts and rests on the stepped feature (132) of the housing (130). During the crimping process, the edge (137) rotates inwardly toward the rotation axis of the housing and rotates downwardly toward the top surface (113) of the connector flange (112). In addition, during the crimping process, the stepped feature (132) provides a force opposite to the crimping force so that the connector (110) is not pushed into the housing (130). The housing (130) can be formed by a stamping process. Therefore, the thickness of the shell wall in the crimping portion (131) of the shell (130) can be substantially equal to the thickness of the shell wall in the base portion (133) of the shell (130), with only a slight change in thickness in a local area. However, the thickness of the shell wall in the base portion (133) and the thickness of the shell wall in the crimping portion (131) can vary depending on the direction of the stamping process. When the direction of the stamping process is a first axial direction, so that the face of the punch (not shown) approaches the shell (130) to contact the base portion (133) of the shell (130), the thickness of the shell wall in the base portion (133) exceeds the thickness of the shell wall in the crimping portion (131). When the direction of the stamping process is a second axial direction, so that the face of the punch (not shown) approaches the shell (130) to contact the crimping portion (131) of the shell (130), the thickness of the shell wall in the crimping portion (131) is thicker than the thickness of the shell wall in the base portion (133). In addition, the thickness of the housing wall in the edge (137) can be thinner than the thickness of the housing wall in the rest of the crimping portion (131), and the thickness of the housing wall in the bottom edge (134) can be thinner than the thickness of the housing wall in the rest of the base portion (133). During the crimping process, the base portion (133) of the housing (130) can be supported by a reinforcing die to prevent the base portion (133) from buckling during the application of the crimping force to the crimping portion (131).

[0050] To further illustrate, Figure 5 Shows Figure 1 and Figure 2 A cross-sectional view of a device (100) wherein Figure 1 and Figure 2 The same reference numerals are used to represent the same parts. Figure 5 As shown, electrical leads (118) extend axially from the interior of cavity (135) of housing (130) through connector (110) to receptacle region (111), which receives, for example, a female plug of an external component (not shown). Figure 3As shown, the port (170) includes an axial passage (171) for introducing fluid from the fluid channel to the sensing element device (160). The axial passage (171) can be, for example, a bore.

[0051] from Figure 5 It can be seen from the details that after crimping, the edge (137) of the crimping portion (131) of the housing (130) has been bent inwardly and downwardly so that the inner wall of the edge (137) is in full contact with the top surface (113) of the connector flange (112). In addition, it can be seen that the bottom surface (115) of the connector flange (112) contacts and rests on the stepped feature (132).

[0052] from Figure 5 As can be seen from the details, in one embodiment, the port (170) includes a welding edge (177). The housing (130) can be welded to the port (170) at the welding edge (177). In other embodiments, the housing (130) can be coupled to the port (170) in other ways that will occur to those skilled in the art.

[0053] Reference now Figure 6 , showing a partial cross-sectional view of a system (600) for crimping a sensor housing according to the present invention. Figure 6 The connector (110) is shown partially inserted into the housing (130) such that the connector flange (112) is completely contained within the crimping portion (131) of the housing (130). The housing (130) is positioned over the port (170). Figure 6 The system for crimping a sensor is shown before the crimping process begins. It can be seen that the connector flange (112) is located below the rim (137) of the housing.

[0054] exist Figure 6In the system, the base support mold (230) is placed around the base portion (133) of the housing (130). The base support mold (230) can be, for example, two semicircular molds clamped together. A first crimping mold (210) is also provided. The first crimping mold (210) includes a curved lip (211) that engages with an edge (137) of the crimping portion (131) of the housing (130) when the first crimping mold (210) is pressed onto the housing, that is, when the first crimping mold (210) approaches the base support mold (230). The first crimping mold (210) is capable of providing support for the crimping portion (131) to prevent the crimping portion (131) from protruding radially outward when the edge (137) is crimped inwardly. In one embodiment, a second crimping mold (220) is also provided. The second crimping die (220) includes a flat surface that presses downwardly on the edge (137) of the crimping portion (131) of the housing (130) so that the inner wall of the edge (137) presses against the top surface (113) of the connector flange (112) and substantially flattens it. The second crimping die (220) can be used in combination with the first crimping die (210) so that the first crimping die (210) provides support to prevent the crimping portion (131) from radially protruding outward during the application of the crimping force by the second crimping die (220). In some embodiments, the second crimping die (210) is used separately from the first crimping die (210) and includes a support member (see Fig.10 ) to prevent the crimping portion (131) from protruding radially outward.

[0055] Although Figure 6 A partial cross-section of the system (600) is shown, but those skilled in the art will appreciate that the first crimping die (210), the second crimping die (220), and the base support die (230) are circumferentially engaged with the housing (130).

[0056] Reference now Figure 7 , shows a partial cross-sectional view of a system (600) for crimping a sensor housing according to the present invention. Figure 6 Same, Figure 7 The connector (110) is shown partially inserted into the housing (130) such that the connector flange (112) is completely contained within the crimping portion (131) of the housing (130). The housing (130) is positioned on the port (170). However, Figure 7 The system (600) is shown after the crimping force applied by the first crimping die (210) is completed. Figure 7 It can be seen that the edge (137) of the crimping portion (131) of the housing (130) has been deformed according to the curvature of the lip (211) of the first crimping die (210). Figure 7It can be further seen that the rim (137) has bent inwardly and now overhangs the connector flange (112). Here, the connector (110) is now secured in the housing (130). In order to reduce the amount of air between the rim (137) and the top surface (113) of the connector flange (112), a second crimping action can be performed by a second crimping die.

[0057] Although Figure 7 A partial cross-section of the system (600) is shown, but one skilled in the art will appreciate that the first crimping die (210), the second crimping die (220), and the base support die (230) are circumferentially engaged with the housing (130).

[0058] Reference now Figure 8 , shows a partial cross-sectional view of a system (600) for crimping a sensor housing according to the present invention. Figure 7 Same, Figure 8 The connector (110) is shown partially inserted into the housing (130) such that the connector flange (112) is completely contained within the crimping portion (131) of the housing (130). The housing (130) is positioned on the port (170). However, Figure 8 The system (600) is shown after the second crimping force applied by the second crimping die (220) is completed. Figure 8 It can be seen that the plane of the second crimping die (220) has further deformed the edge (137) of the crimping portion (131) of the housing (130) so that the inner wall of the edge (137) is now substantially parallel to and in contact with the top surface (113) of the connector flange (112).

[0059] Although Figure 8 A partial cross-section of the system (600) is shown, but one skilled in the art will appreciate that the first crimping die (210), the second crimping die (220), and the base support die (230) are circumferentially engaged with the housing (130).

[0060] After the crimping is completed, a sealant (120) made of a material such as silicone, glue, etc. may be applied over the entire circumference between the connector (110) and the crimping portion (131) of the housing (130) (see Figure 2 ) to form an additional seal to prevent liquid, water, air or matter from entering the cavity (135) of the housing (130) after crimping.

[0061] Reference now Fig. 9, shows a first crimping die (310) and a second crimping die (320) according to an embodiment of the present invention. The first crimping die (310) includes a crimping lip (311) having a curvature (312), which bends toward the radial axis of the crimped housing during operation. The first crimping die (310) also includes a radial constraint portion (313), which provides radial support to the crimping portion of the housing during the first crimping action of the first crimping die (310). The radial constraint portion (313) also provides radial support to the crimping portion of the housing during the second crimping action through the second crimping die (320). The second crimping die (320) includes a flat downward pressing end portion (321), which pushes the edge of the crimping portion of the housing downward toward the flange of the connector during the second crimping action.

[0062] Reference now Fig.10 , shows a first crimping mold (410) and a second crimping mold (420) according to another embodiment of the present invention. Fig. 9 The second crimping die (320), Fig.10 The second crimping die (420) is used for a second crimping action that is completely separated from the first crimping action, that is, after the first crimping action has been completed and the first crimping die (410) has released the housing. The first crimping die (410) includes a crimping lip (411) with a curvature (412), which is bent toward the radial axis of the crimped housing during operation. The first crimping die (410) also includes a radial constraint portion (413), which provides radial support to the crimping portion of the housing during the first crimping action of the first crimping die (410). The second crimping die (420) includes a flat push-down end portion (421), which pushes the edge of the crimping portion of the housing downward toward the flange of the connector during the second crimping action. The second crimping die (420) also includes a radial constraint portion (423), which provides radial support to the crimping portion of the housing during the second crimping action of the second crimping die (420).

[0063] Reference now Fig.11 , showing a perspective view of a housing (530) according to another embodiment of the present invention. The housing (530) includes a stepped feature (132) as a plurality of notches (531) formed on the exterior of the housing, which serve as protrusions (539) on the interior wall of the housing (see Fig.18) translates through the shell wall. Multiple notches (531) formed on the exterior and interior of the shell may also provide bending and torsional stiffness to the thin-walled shell, thereby providing enhanced load absorption in all six degrees of freedom. The notches (531) may be formed by metalworking methods that will be recognized by those skilled in the art. For example, multiple notches (531) may be formed in the shell by pushing a tool radially inward in the thin-shell shell wall after the connector has been assembled (not shown). The protrusions (539) on the interior of the shell formed by the notches (531) are arranged to correspond to the grooves (not shown) in the connector flange so that the connector is located on the protrusions on the inner wall of the shell formed by the notches (531).

[0064] Reference now Fig.18 , showing a plan view of the housing (530). The inner wall (537) of the cavity (535) of the housing (530) includes Fig.11 The connector includes a protrusion (539) corresponding to the notch (531) shown in the figure. Each protrusion (539) corresponds to and is aligned with a groove (not shown) on the bottom surface of the connector flange (112). The groove can be, for example, a notch in the flange (112), so that when the connector is inserted into the cavity and the groove (not shown) and the protrusion (539) are aligned, each groove in the flange is located on the protrusion (539).

[0065] Reference now Fig.12 , shows a connector (610) according to another embodiment of the present invention. Fig.12 The top surface of the connector is shown. The connector (610) can have anti-rotation pits (618) pre-formed in the flange (612) of the connector (610). Although shown as being on the top surface of the connector (610), the anti-rotation pits (618) can be additionally or alternatively on the bottom surface of the connector (610) (not shown). When the anti-rotation pits are located on the bottom side of the flange (612), the shape of these anti-rotation pits can be a narrow (negative) shape of multiple protrusions (539) formed inside the housing (not shown). The first crimping die can include die protrusions that form one or more corresponding pits in the edge of the crimping portion during the crimping process, engaging with the pits (618) in the flange (612) of the connector (610), thereby inhibiting the rotation of the connector (610) in the housing.

[0066] To further illustrate, Fig.13A flow chart is shown, which illustrates an exemplary method for assembling a sensor having a crimped housing according to an embodiment of the present invention, the method comprising receiving (1310) a stamped tubular housing on a sensor port, the housing comprising a crimp portion, a base portion, and a stepped feature formed in the housing, the stepped feature separating the crimp portion from the base portion. Receiving (1310) the stamped tubular housing on the sensor port may be performed by an assembler that receives the housing (130) positioned on the port (170) (see Figure 2 ), the housing includes a crimping portion, a base portion, and a stepped feature formed in the housing, the stepped feature separating the crimping portion from the base portion. The housing (130) can be coupled to the port (170) before the assembler receives the housing (130) and the port (170) or in a subsequent step, for example, by welding. The housing (130) can be a cylinder, a tube, or other suitable shape with an open cavity (135). The housing (130) includes a crimping portion (131), which is a deformable portion of the housing suitable for bending and crimping (see Figure 3 The housing (130) further comprises a base portion (133) in which the sensor components are housed (see Figure 3 The housing (130) further includes a stepped feature (132), which may be, for example, an annular boss or a plurality of protrusions. The stepped feature (132) may be formed on the inner wall of the housing (130) based on any suitable metalworking operation before the assembler receives the housing (130) and the port (170).

[0067] exist Fig.13 In an exemplary method, the housing and the sensor port may be provided with sensor components already provided inside the housing, such as by inserting the sensor element (160) into the cavity (135) of the housing (130) by an assembler (see Figure 2 ). The assembler then inserts the pressure sensor circuit (150) into the cavity (135) above the sensor element (160) (see Figure 2 ).

[0068] Fig.13 The exemplary method also includes inserting (1330) at least a portion of the electrical connector into the housing, including positioning an annular flange of the electrical connector within a crimping portion of the housing so that a bottom surface of the flange contacts the stepped feature. Inserting (1330) at least a portion of the electrical connector into the housing, including positioning an annular flange of the electrical connector within a crimping portion of the housing so that a bottom surface of the flange contacts the stepped feature, can be performed as follows: The assembler inserts at least a portion of the connector (110) (i.e., the flange (112)) into the cavity (135) of the housing (130) above the pressure sensor circuit (150) (see Figure 2 The connector is aligned with the flexible printed circuit board (140) so that the leads (118) of the connector make electrical contact with the conductors (141) on the flexible printed circuit board (140). The top surface (113) of the connector flange is located below the upper edge (137) of the crimping portion (131) of the housing (130) (see Figure 4 The bottom surface (115) of the connector flange (112) contacts and rests on the stepped feature (132) of the housing (130) (see Figure 4 ).

[0069] Fig.13 The exemplary method also includes placing (1340) a support mold around the base portion of the shell. Placing (1340) the support mold around the base portion of the shell can be performed by placing a base support mold (230) around the base portion (133) of the shell (130) assembler (see Fig.15 ). The base support mold (230) may be, for example, two semicircular molds clamped together.

[0070] Fig.13 The exemplary method also includes crimping (1350) a crimping portion of the housing onto the flange such that an edge of the crimping portion is bent onto a top surface of the flange. Fig.15 and Fig.16 The crimping portion (1350) of the housing is crimped onto the flange so that the edge of the crimping portion is bent onto the top surface of the flange by lowering a die press including at least one die (210) onto the crimping portion (131) of the housing (130) so that the edge (137) of the crimping portion (131) is rotated inwardly toward the rotation axis of the housing and downwardly toward the top surface (113) of the connector flange (112) (see Fig.15 ). For example, when the first mold (210) contacts the base support mold (230) (see Fig.16 ), the first crimping action is completed.

[0071] To further illustrate, Fig.14 A flow chart illustrating another exemplary method for assembling a sensor having a crimp housing according to an embodiment of the present invention is set forth. Fig.13 Same, Fig.14 It includes receiving (1310) a stamped tubular shell on a sensor port, the shell including a crimping portion, a base portion, and a stepped feature portion formed in the shell, the stepped feature portion separating the crimping portion from the base portion, placing (1340) a supporting die around the base portion of the shell, crimping (1350) the crimping portion of the shell onto a flange so that the edge of the crimping portion is bent onto the top surface of the flange.

[0072] Fig.14 An exemplary method and Fig.13 The exemplary method is different in that crimping (1350) the crimping portion of the housing onto the flange so that the edge of the crimping portion is bent onto the top surface of the flange further includes bending (1410) the edge of the crimping portion inwardly toward the rotation axis of the housing by a first crimping die so that the edge overhangs the top surface of the flange. Bending (1410) the edge of the crimping portion inwardly toward the rotation axis of the housing by the first crimping die so that the edge overhangs the top surface of the flange can be performed by lowering a die press including a first crimping die (210) onto the crimping portion (131) of the housing (130) so that the edge (137) of the crimping portion (131) is rotated inwardly toward the rotation axis of the housing and rotated downwardly toward the top surface (113) of the connector flange (112) (see Fig.15 ). For example, when the first mold (210) contacts the base support mold (230) (see Fig.16 ), the first crimping action is completed. During the bending (1410) of the edge (137) of the crimping portion, the radial constraint portion (313) of the first crimping die (210) provides support for the remaining crimping portion to prevent the crimping portion (131) from bulging outward during the crimping process. Bending the edge of the crimping portion inwardly toward the rotation axis of the housing by the first crimping die (1410) so that the edge hangs over the top surface of the flange may include generating a pit in the edge of the crimping portion by the crimping die protrusion.

[0073] Fig.14 An exemplary method and Fig.13 The exemplary method is also different in that crimping (1350) the crimping portion of the housing onto the flange so that the edge of the crimping portion is bent onto the top surface of the flange further includes bending (1420) the edge of the edge toward the top surface of the flange by a second crimping die so that the inner wall of the edge contacts the top surface of the flange. Bending (1420) the edge of the edge toward the top surface of the flange by the second crimping die so that the inner wall of the edge contacts the top surface of the flange can be performed by lowering a die press including the second crimping die (220) onto the edge (137) of the crimping portion (131) of the housing (130) that has been bent inward by the first crimping die (see Fig.17). The second crimping die (220) includes a flat surface that presses downwardly on the edge (137) of the crimping portion (131) of the housing (130). The inner wall of the edge (137) is substantially flat against the top surface (113) of the connector flange (112). The second crimping action of the second crimping die (220) can significantly reduce the amount of air between the edge (137) and the top surface (113) of the connector flange (112). A strip of sealant can be applied to the joint between the edge (137) and the top surface (113) of the connector flange (112) to further seal the sensor device. After the second crimping action of the second crimping die (220) is completed, the die press including the first crimping die (210) and the second crimping die (220) can be raised, and the base support die (230) can be removed to retrieve the sensor device.

[0074] It should be noted that the techniques herein are well suited for use in any type of sensor application, such as the pressure sensor assemblies and temperature sensor assemblies discussed herein. However, it should be noted that the embodiments herein are not limited to use in such applications, and the techniques discussed herein are also well suited for other applications.

[0075] It can be understood from the foregoing description that the various embodiments of the present invention may be modified and altered without departing from the true spirit of the present invention. The descriptions in this specification are for illustration only and should not be interpreted as having a restrictive meaning. The scope of the present invention is limited only to the language of the following claims.

Claims

1. A sensor device, comprising: Sensor port; a thin-walled tubular housing coupled to the sensor port and including a crimp portion, a base portion, and a stepped feature formed in the housing, the stepped feature separating the crimp portion from the base portion; a sensor component disposed within the base portion of the housing; as well as an electrical connector coupled to the housing and including leads electrically coupled to the sensor component and a connector flange, wherein an edge of a crimping portion of the housing is crimped onto the connector flange to retain the electrical connector in the housing; The stepped feature portion includes a plurality of protrusions formed on an inner surface of the housing, and the plurality of protrusions correspond to a plurality of grooves on the connector flange of the electrical connector.

2. The sensor device according to claim 1, wherein the sensor component comprises: Sensing element; an electronic circuit electrically coupled to the sensing element; as well as One or more electrical conductors are electrically coupled to the electronic circuit, wherein leads of the connector are electrically coupled to the one or more electrical conductors. 3 . The sensor of claim 2 , wherein the one or more electrical conductors include at least one of a flexible printed circuit board, a plurality of electrical wires having a connector at each end, and a plurality of soldered wires.

4. The sensor device of claim 1, wherein the stepped feature of the housing comprises an annular boss, and wherein the annular boss supports the flange and provides bending and torsional stiffness to the housing during crimping of the crimping portion. The sensor device of claim 1 , wherein the housing is formed by a stamping process.

6. The sensor device according to claim 5, wherein the thickness of the housing wall in the base portion and the thickness of the housing wall in the crimping portion of the housing vary depending on the direction of the stamping process, wherein when the direction of the stamping process is a first direction, the thickness of the housing wall in the base portion exceeds the thickness of the housing wall in the crimping portion, and Wherein when the direction of the punching process is the second direction, the thickness of the shell wall in the crimping portion exceeds the thickness of the shell wall in the base portion.

7. The sensor device according to claim 1, wherein the sensor is a pressure sensor, the sensor component comprises at least a sensing element for measuring fluid pressure and a pressure sensor circuit coupled to the sensing element to convert the pressure sensed by the sensing element into an electronic signal, and the port comprises a channel for introducing the fluid into the sensing element.

8. The sensor device according to claim 1, wherein the sensor is a temperature sensor, the sensor component comprises at least a sensing element for measuring a temperature of a fluid and a temperature sensor circuit coupled to the sensing element to convert the temperature sensed by the sensing element into an electronic signal, and the port comprises a channel for introducing the fluid into the sensing element.

9. A method of assembling a sensor device having a crimp housing, comprising the steps of: providing a thin-walled tubular housing over the sensor port, the housing including a crimp portion, a base portion, and a stepped feature formed in the housing, the stepped feature separating the crimp portion from the base portion, wherein a sensor component is disposed within the housing; inserting at least a portion of an electrical connector into the housing, including disposing an annular flange of the electrical connector within a crimping portion of the housing such that a bottom surface of the flange contacts the stepped feature; placing a support mold around a base portion of the shell; as well as The crimping portion of the housing is crimped onto the flange so that the edge of the crimping portion is bent onto the top surface of the flange, which comprises the following steps: By means of a first crimping die, the edge of the crimping portion is bent inwardly toward the rotation axis of the housing so that the edge overhangs the top surface of the flange; as well as The edge of the rim is bent toward the top surface of the flange by one or more second crimping dies, so that the inner wall of the rim contacts the top surface of the flange.

10. The method according to claim 9, wherein the first crimping die includes a curved lip and a radial restraint portion, and wherein when the first crimping die approaches the supporting die during crimping, the crimping portion is deformed according to the curvature of the lip, and wherein the radial restraint portion prevents the crimping portion of the shell from bulging outward.

11. The method of claim 9, wherein the first crimping die includes a plurality of protrusions that form recesses in an edge of the crimping portion during crimping to engage with corresponding recesses in the flange, thereby inhibiting rotation of the connector in the housing.

12. The method of claim 9, wherein the one or more second crimping dies include a flat end for pushing an edge of the crimping portion against a top surface of the flange after the edge of the crimping portion is bent by the first crimping dies.

13. The method of claim 9, wherein the stepped feature of the housing comprises an annular boss, and wherein the annular boss supports the flange during crimping of the crimping portion.

14. The method of claim 9, wherein the stepped features include a plurality of protrusions formed on the inner surface of the housing corresponding to a plurality of grooves in a flange of the electrical connector.

15. The method of claim 9, wherein the housing is formed by a stamping process.

16. The method according to claim 15, wherein the thickness of the housing wall in the base portion and the thickness of the housing wall in the crimping portion of the housing vary depending on the direction of the stamping process, wherein when the direction of the stamping process is a first direction, the thickness of the housing wall in the base portion exceeds the thickness of the housing wall in the crimping portion, and Wherein when the direction of the punching process is the second direction, the thickness of the shell wall in the crimping portion exceeds the thickness of the shell wall in the base portion.

17. The method according to claim 9, wherein the sensor is a pressure sensor, the sensor component includes at least a sensing element for measuring fluid pressure and a pressure sensor circuit coupled to the sensing element to convert the pressure sensed by the sensing element into an electronic signal, and the port includes a channel for introducing the fluid into the sensing element.

18. The method according to claim 9, wherein the sensor is a temperature sensor, the sensor component comprises at least a sensing element for measuring the temperature of a fluid and a temperature sensor circuit coupled to the sensing element to convert the temperature sensed by the sensing element into an electronic signal, and the port comprises a channel for introducing the fluid into the sensing element.

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