Sensor device

Abstract

In a particular embodiment, a force sensor apparatus is disclosed that includes a sensor housing and a sensing assembly. In this particular embodiment, the sensing assembly includes a force compliant element having a central portion and an outer portion; one or more sensing elements coupled to the central portion of the force compliant element; and a flexible spring element having an outer diameter and a central portion. According to at least one embodiment of the present disclosure, the flexible spring element is curved from the outer diameter to the central portion of the flexible spring element, and the central portion of the flexible spring element is aligned with the central portion of the force compliant element. In this embodiment, the outer diameter is spaced apart from a ledge of the outer portion of the force compliant element by a space.

Description

BACKGROUND

[0001] Force sensors are commonly used to control or regulate a force applied to a component. In one type of force sensor, the force sensor is positioned such that the force to be measured acts on the sensor. The force sensor can be configured to convert the measurement of the force into an electrical signal for further control or regulation of the force. This type of force sensor can be used in various applications, such as for measuring the braking force of an electromechanical brake in a vehicle, etc. For example, a force compliant element of the force sensor can be coupled to a component of the braking system, and when a force is applied, the force compliant element temporarily deforms. In this example, the strain on the force compliant element can be measured and used to generate an electrical signal indicative of the force acting on the component of the braking system.

[0002] With this type of sensor, parasitic forces, such as side loads or non-concentric support regions, etc., can cause a non-uniform load. The non-uniform load can cause a shift in the location of the strain field on the force compliant element of the force sensor, which will affect the accuracy of the force sensor and can increase the stress / strain in the silicon glass that can be used to bond the sensing elements of the sensor. The components of the force sensor can also be damaged from overloading. SUMMARY

[0003] The above and other objects, features and advantages of the present application will become apparent from the following more detailed description of illustrative embodiments thereof, which description should be taken in conjunction with the accompanying drawings.

[0004] In a particular embodiment of the present disclosure, a force sensor device is disclosed that includes a sensor housing and a sensing assembly. In this particular embodiment, the sensing assembly includes a force compliant element, one or more sensing elements coupled to a central portion of the force compliant element, and a flexible spring element. According to at least one embodiment of the present disclosure, the flexible spring element is curved from an outer diameter to a central portion of the flexible spring element, and the central portion of the flexible spring element is aligned with a central portion of the force compliant element. In this embodiment, the outer diameter is spaced apart from a ledge of an outer portion of the force compliant element by a space. The flexible spring element is configured to bend in response to a range of forces applied to the outer diameter such that when a force from the outer diameter of the flexible spring element is transmitted to the central portion of the flexible spring element and applied to the central portion of the force compliant element, the outer diameter moves within the space toward the ledge until an additional force beyond the range is applied to the outer diameter such that the outer diameter is pressed against the ledge at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing. As will be explained below, the ledge acts as a hard stop that prevents the central portion of the spring element from being pressed further against the central portion of the force compliant element. In this example embodiment, the force compliant element is configured to deform in response to the application of force from the central portion of the flexible spring element. According to this embodiment, the one or more sensing elements generate one or more signals indicative of an extent to which the force compliant element has deformed in response to the application of force from the central portion of the flexible spring element.

[0005] As will be explained further below, one advantage of using an integrated spring element with a hard stop is that the force compliant element can be protected from overloading and the risk of introducing side loads into the force compliant element can be reduced.

[0006] In a particular embodiment, a force sensor device includes a sensor housing, a connector inserted into the sensor housing, a solder ring compressed between the sensor housing and the connector, and a sensing assembly coupled to the sensor housing. In this embodiment, the sensing assembly includes a force compliant element having a central portion and an outer portion. One or more sensing elements are coupled to the central portion of the force compliant element. The force compliant element deforms in response to an application of force to the force compliant element, and the one or more sensing elements generate one or more signals indicative of an extent to which the force compliant element deforms in response to the application of force to the force compliant element.

[0007] As will be explained below, the weld ring can be used to decouple the (high) forces required for the environmental sealing of the sensor device and the (low) forces required to electrically connect the connector to the electrical components, so that both the environmental sealing and the electrical compression can be more controlled. This can greatly expand the possible tolerances between components, allowing for reduced costs and increased freedom of component selection (e.g., O-rings, springs, etc.). Another benefit is that the rigidity of the connector to housing assembly can be significantly higher due to the decoupling of forces. This can allow for higher installation forces and reduced parasitic effects from harness variations. Furthermore, the design of the sensor assembly allows for improved weldability due to the reduced gap of the weld ring.

[0008] In a particular embodiment, a method of assembling a force sensor device is disclosed, the method comprising compressing an environmental seal between a sensor housing and a connector using a weld ring by inserting the connector into the sensor housing. The method further comprises inserting a sensing assembly into the sensor housing. In this embodiment, the sensing assembly comprises a force compliant element having a central portion and an outer portion; and one or more sensing elements coupled to the central portion of the force compliant element and a printed circuit board (PCB). In this particular embodiment, the force compliant element deforms in response to an application of a force to the force compliant element, and the one or more sensing elements generate one or more signals indicative of a degree to which the force compliant element deforms in response to the application of the force to the force compliant element. The method further comprises coupling a spring element of the connector to the PCB of the sensing assembly. Furthermore, the method further comprises coupling the sensing assembly to the sensor housing. BRIEF DESCRIPTION OF DRAWINGS

[0009] FIG. 1A is a schematic diagram illustrating a cross-sectional view of a sensor device under a load within a normal operating range, in accordance with at least one embodiment of the present disclosure;

[0010] FIG. 1B is a schematic diagram illustrating a cross-sectional view of a sensor device under a load exceeding a normal operating range of the sensor device, in accordance with at least one embodiment of the present disclosure; FIG. 1A

[0011] FIG. 2A is a finite element analysis (FEA) plot depicting a maximum normalized elastic strain on a membrane when a load within a normal operating range of a sensor device is applied to a dedicated interface, in accordance with at least one embodiment of the present disclosure; FIG. 1A

[0012] FIG. 2B is a FEA plot depicting an elastic strain on a membrane of a prior art sensor device when a load exceeds a normal operating range of the prior art sensor device;

[0013] ​​FIG. 2C is an FEA plot according to at least one embodiment of the present disclosure, which depicts the elastic strain on the membrane when a load exceeding the normal operating range of the sensor device is applied to the dedicated interface FIG. 1B

[0014] FIG. 3 is a schematic diagram illustrating an FEA plot, which depicts the directional deformation of the force compliant element;

[0015] FIG. 4 is a schematic diagram illustrating a cross-sectional view of a connector assembly according to at least one embodiment of the present disclosure;

[0016] FIG. 5 is a schematic diagram illustrating a view of a connector assembly according to at least one embodiment of the present disclosure; FIG. 4

[0017] FIG. 6A is a schematic diagram illustrating a cross-sectional view of a connector assembly according to at least one embodiment of the present disclosure, with a portion of the connector assembly inserted into the sensor housing; FIG. 4 FIG. 5

[0018] FIG. 6B is a schematic diagram illustrating a cross-sectional view of a connector housing assembly according to at least one embodiment of the present disclosure, which is formed by fully inserting the connector assembly of FIG. 4 and FIG. 5 into the sensor housing of FIG. 6A ;

[0019] FIG. 7A is a schematic diagram illustrating a cross-sectional view of a connector housing assembly according to at least one embodiment of the present disclosure, which is partially inserted into the sensing assembly; FIG. 6B

[0020] FIG. 7B is a schematic diagram illustrating a cross-sectional view of an assembled sensor device according to at least one embodiment of the present disclosure, which is formed by fully inserting the connector housing assembly into the sensing assembly;

[0021] FIG. 8 is a schematic diagram illustrating a cross-sectional view of an assembled sensor device according to at least one embodiment of the present disclosure;

[0022] FIG. 9 is a schematic diagram illustrating an isometric cross-sectional view of an assembled sensor device according to at least one embodiment of the present disclosure;

[0023] FIG. 10 ​​​​​is a schematic diagram illustrating an isometric cross-section view of an assembled sensor device according to at least one embodiment of the present disclosure;

[0024] FIG. 11 is a schematic diagram illustrating an isometric cross-section view of an assembled sensor device according to at least one embodiment of the present disclosure; and

[0025] FIG. 12 is a flowchart illustrating an embodiment of a method for assembling a force sensor device according to at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0026] The advantages and other features of the devices disclosed herein will become more apparent from the following detailed description of certain embodiments when taken in conjunction with the drawings.

[0027] In the description herein, throughout the drawings, common features are designated by common reference numerals. As used herein, different terminology is used for the purpose of describing particular embodiments only and is not intended to be limiting. For example, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It can be further understood that the terms “comprise,” “comprises,” and “comprising” can be used interchangeably with “include,” “includes,” or “including.” Additionally, it will be understood that the term “wherein” can be used interchangeably with “where.” As used herein, “exemplary” can indicate an example, an implementation, and / or an aspect, and should not be construed as a limitation or indicating a preference or a preferred implementation. As used herein, ordinal terms such as “first,” “second,” “third,” etc. used in connection with an element of description, such as a structure, a component, an operation, etc., do not by themselves indicate any priority or order of the element with respect to another element, but are simply used to distinguish that element from another element having a same name but for use of the ordinal term. As used herein, the term “set” refers to a grouping of one or more elements, and the term “plurality” refers to multiple elements.

[0028] As used herein, “coupled” can include “communicatively coupled,” “electrically coupled,” or “physically coupled,” and can also (or alternatively) include any combination thereof. Two devices (or components) can be coupled (e.g., communicatively coupled, electrically coupled, or physically coupled) directly or indirectly via one or more other devices, components, wires, etc. As an illustrative, non-limiting example, two devices (or components) that are electrically coupled can be included in the same device or different devices and can be connected via electronics, one or more connectors, or inductive coupling. In some implementations, two devices (or components) that are communicatively coupled, such as in electrical communication, can send and receive electrical signals (digital or analog) directly or indirectly, such as via one or more wires, buses, networks, etc. As used herein, “directly coupled” can include two devices that are coupled (e.g., communicatively coupled, electrically coupled, or physically coupled) without intermediate components.

[0029] Furthermore, words of orientation such as “upper,” “lower,” “inner,” and “outer” are used only to assist in describing the location of components relative to one another. For example, an “inner” surface of a component is merely intended to describe a surface that is separate from an “outer” surface of the same component. No words of orientation are used to describe absolute orientation (i.e., where the “inner” portion must always be inside the component).

[0030] Note that the technology herein is well suited for use in any type of sensor application, such as the force sensor assemblies discussed herein. However, it should be noted that the embodiments herein are not limited to use in such applications, and the technology discussed herein is well suited for use in other applications as well.

[0031] In force sensors, a distinction can be made between normal loads (forces for normal operation) and verification loads (overload forces that should not affect the functioning of the sensor within the normal operating range). In particular embodiments, the verification force can be 500% larger than the normal operating force. Avoiding damage to the elements of the sensor device for a force that is 5 times the operating force becomes a significant challenge. The present disclosure describes embodiments of force sensor devices that include spring elements with hard stops. As will be explained below, one advantage of using integrated spring elements with hard stops is that the force compliant elements of the force sensor device can be protected from overload and the risk of introducing side loads into the force compliant elements can be reduced.

[0032] FIG. 1A is a schematic diagram illustrating a cross-sectional view of a sensor device (100) having a load within a normal operating range, in accordance with at least one embodiment of the present disclosure. FIG. 1B is a schematic diagram illustrating a cross-sectional view of a sensor device (100) having a load within a normal operating range, in accordance with at least one embodiment of the present disclosure. FIG. 1AFIG. 1 is a schematic diagram of a cross-sectional view of a sensor device (100) having a load exceeding a normal operating range of the sensor device (100).

[0033] FIG. 1A and FIG. 1B The sensor device (100) includes a dedicated interface (109), a sensor housing (105), a disk (101), a flexible spring element (102), a force compliant element (103), a membrane (104), a plurality of sensing elements (106), a PCB (107), and PCB components (108).

[0034] In FIG. 1A and FIG. 1B In an example, the disk (101) has a first surface coupled to the dedicated interface (109) and has a second surface coupled to an outer diameter (140) of the flexible spring element (102). The flexible spring element (102) also has a central portion (142) that is aligned with a central portion (160) of the force compliant element (103), and the flexible spring element (102) is curved from the outer diameter (140) to the central portion (142) of the flexible spring element (102). In FIG. 1A and FIG. 1B In an example, the outer diameter (140) of the flexible spring element (102) is spaced apart from a ledge (152) of an outer portion of the force compliant element (103) by a space (150).

[0035] During operation, a force (120) applied to the dedicated interface (109) is first transmitted to the disk (101) and subsequently to the outer diameter (140) of the flexible spring element (102). The flexible spring element (102) is configured to bend in response to a force within a normal operating range applied to the outer diameter (140) of the flexible spring element (102) such that the outer diameter (140) moves within the space (150) toward the ledge (152) when the force is transmitted from the outer diameter (140) to the central portion (142) of the flexible spring element (102) and applied to the central portion (160) of the force compliant element (103).

[0036] The application of this load can cause bending of the force-compliant element (103) and a change in strain on the membrane (104). Multiple sensing elements (106) can be attached to the membrane (104) via glass to measure the strain changes on the force-compliant element (103) and the membrane (104). Each sensing element (106) can be configured to generate a signal indicating the degree to which the force-compliant element (103) and the membrane (104) deform in response to the application of forces in opposite directions. In a specific embodiment, the sensing element is a microfused silicon strain gauge (MSG). To measure the amount of force applied to the force-compliant element (103), the sensing elements (106) can be uniformly distributed on a circle on the top surface of the force-compliant element (103). Those skilled in the art will recognize that any number of sensing elements placed in various configurations can be used according to this disclosure. Signals from the sensing elements (106) can be transmitted via electrical connections (not shown) to electrical components (integrated circuits and passive components such as resistors, capacitors, etc.) on the PCB (107).

[0037] like FIG. 1B As shown, when an additional force (195) exceeding the normal operating range is applied to the outer diameter (140), the outer diameter (140) moves toward the lug (152) of the force-compliant element (103), causing the outer diameter (140) to press against the lug (152). In this example, the contact between the outer diameter (140) of the flexible spring element (102) and the lug (152) of the force-compliant element (103) acts as a hard stop to prevent the central portion (142) of the flexible spring element (102) from moving further toward the central portion (160) of the force-compliant element (103). FIG. 1B As indicated by arrows (182, 190), a load exceeding the normal operating range causes the spring element (102) to reach the hard stop, and the force will not be directed through the central portion of the force-compliant element to the diaphragm (104), but rather directed to the outer portion of the force-compliant element to the sensor housing (105). In a specific embodiment, the spring element is optimized for the desired displacement of the required protective force and load.

[0038] The sensor housing (105) is designed to protect the electrical components of the force sensor device (100) and to receive the reaction force used for force measurement. Although not shown, FIG. 1A and FIG. 1B The device (100) may also include an electronic connector that is aligned for positioning within an opening in the sensor housing (105).

[0039] In a specific embodiment, there is no fixed connection between the disc (101) and the spring element (102) and / or between the spring element (102) and the force-compliant element (103). This significantly reduces parasitic loads in the force-sensing element. In another specific embodiment, the spring element (102) is designed with a different contact shape, either a point contact or a (circular) line contact. The flexibility within the spring element allows for a more uniform load distribution on the force-compliant element. Because... FIG. 1A and FIG. 1B The force sensor device (100) has an integrated spring element with a hard stop, which protects the force compliant element from overload and reduces the risk of introducing lateral loads into the force compliant element.

[0040] Those skilled in the art will recognize that both the dedicated interface (109) and the sensor housing (105) can be adapted and modified to integrate the device (100) into any component of a new or existing assembly to directly measure force or measure the reaction force associated with the force. For example, in a typical brake pedal assembly, a pushrod extends from the floor area in front of the engine compartment. At one end of the pushrod, it is coupled to a rotary joint attached to the floor. The foot pedal may be attached to the other end of the pushrod. At a point between the two ends of the pushrod, it is coupled to a piston, which is coupled to the braking system. In this exemplary brake pedal assembly, the device (100) can be integrated into multiple locations. For example, the sensor device of this disclosure can also be coupled to measure the force at the connection between the pushrod and the piston, the force at the connection between the pushrod and the floor, and the force applied to the floor. Alternatively, the sensor device described in this disclosure can be coupled to the brake pedal to measure the tensile or compressive force applied when the user presses the pedal.

[0041] FIG. 2A The figure illustrates a finite element analysis (FEA) diagram (202) according to at least one embodiment of the present disclosure, which depicts the situation when a load within the normal operating range of the sensor device (100) is applied to the application-specific interface (109). FIG. 1A The maximum normalized elastic strain on the membrane (104). FIG. 2A In the example, the device (100) is configured to have a normal operating range such that the spring element (102) is configured to reach the hard stop under maximum load at the end of the normal operating range. FIG. 2AAs shown, when a normal operating load is applied to the sensor device (100), the load is transferred from the dedicated interface (109) to the disk (101) and from the disk (101) to the spring element (102). Because the load is within the normal operating range of the sensor device (100), the spring element (102) transfers a similar load to the force-compliant element (103). This causes bending of the force-compliant element (103) and a change in strain on the membrane (104), which in FIG. 2A The FEA diagram (202) is shown. FIG. 2A The FEA diagram (202) shows that the elastic strain on the membrane is within acceptable limits and remains below the critical threshold.

[0042] FIG. 2B The diagram shows a finite element analysis (FEA) diagram (204), which depicts the elastic strain on the membrane of a prior art sensor device when the load exceeds the normal operating range of the prior art sensor device. FIG. 2B The existing sensor devices used are configured to have a normal operating range, with a maximum load at the end of the normal operating range. Existing sensor devices do not include disc or spring elements with hard stops. Therefore, when an operating load exceeding the maximum load and normal operating range is applied to the existing sensor device, there is no spring element to prevent the load from exceeding the sensor device's limits. Excess strain on the existing sensor device is reflected in… FIG. 2B In the FEA diagram (204), it is shown that the strain on the membrane exceeds the acceptable limits and critical thresholds of the sensor device. As explained above, when forces or loads exceeding the normal operating range of prior art sensor devices are applied to them, the force-compliant elements, sensing elements, and glass binders may be damaged.

[0043] FIG. 2C This is a finite element analysis (FEA) diagram (206) according to at least one embodiment of the present disclosure, which depicts the situation when a load exceeding the normal operating range of the sensor device is applied to the application-specific interface (109). FIG. 1B The elastic strain on the membrane (104). For example... FIG. 2CAs shown, when an operating load beyond the maximum load and normal operating range of the sensor device (100) is applied to the sensor device (100), the load is transferred from the application specific interface (109) to the disc (101) and from the disc (101) to the spring element (102). Because the force from the operating load on the specific application interface (109) exceeds the maximum load and normal operating range of the force sensor device, the spring element (102) will deform such that the spring element (102) will reach a hard stop at the maximum load limit and the force will not be directed through the force compliant element (103) to the membrane (104) but rather through the force compliant element to the sensor housing (105). When compared to the FEA plot (204) of FIG. 2B , this redirection of force is evident in the FEA plot (206) of FIG. 2C . With the hard stop and optimized spring design for the maximum load (to reach the hard stop), the elastic strain on the membrane will be significantly reduced. As shown in the FEA plot (206) of FIG. 2C , even if the load applied to the sensor device exceeds the normal operating range of the sensor device, the elastic strain remains below the critical threshold of the sensor device.

[0044] FIG. 3 is an FEA plot (300) depicting the directional deformation of a force compliant element. As shown in the example of FIG. 3 , the force compliant element has a small displacement at the maximum load and is too stiff (too small displacement) to integrate a hard stop. By increasing the spring element (e.g., the spring element (102) of FIG. 1A , the displacement will increase to an acceptable level (as illustrated by the reduction in stiffness in FIG. 4 , such that a hard stop can be integrated into the design of the sensor device.

[0045] FIG. 4 is a schematic diagram illustrating a cross-sectional view of a connector assembly (404) in accordance with at least one embodiment of the present disclosure. FIG. 5 is a schematic diagram illustrating a view of the connector assembly (404) of FIG. 4 . Referring to FIG. 4 , the connector assembly (404) includes a connector (401) and an O-ring (402) surrounding the body of the connector (401). The connector assembly also includes a metal weld ring (403) and an electrical connection (420). In particular embodiments, the weld ring can be flexible and compressible. In other embodiments, the weld ring can be rigid.

[0046] FIG. 6A is a schematic diagram illustrating a partial insertion of the connector assembly (404) into a sensor housing (602) in accordance with at least one embodiment of the present disclosure. FIG. 4 and FIG. 5is a schematic diagram illustrating a cross-sectional view of a connector assembly (404) according to at least one embodiment of the disclosure. FIG. 6B is a schematic diagram illustrating a cross-sectional view of a connector housing assembly (690) according to at least one embodiment of the disclosure, which is formed by fully inserting the connector assembly (404) into a sensor housing (602). FIG. 4 and FIG. 5 is a schematic diagram illustrating a cross-sectional view of a connector assembly (404) according to at least one embodiment of the disclosure. FIG. 6A is a schematic diagram illustrating a cross-sectional view of a connector assembly (404) according to at least one embodiment of the disclosure. FIG. 6B Referring to

[0047] In particular embodiments, the connector assembly (404) and the housing (602) can be rigidly connected in the radial direction at the weld location (650) using a variety of methods including, but not limited to, (spot) welding, crimping, and gluing. In this embodiment, after the connector assembly (404) is rigidly connected with the housing (602), the connector (401) cannot move axially anymore due to the fixed weld ring (403).

[0048] FIG. 7A is a schematic diagram illustrating a cross-sectional view of a connector housing assembly (690) according to at least one embodiment of the disclosure, which is partially inserted into a sensing assembly (700). FIG. 6B is a schematic diagram illustrating a cross-sectional view of a connector housing assembly (690) according to at least one embodiment of the disclosure, which is partially inserted into a sensing assembly (700). FIG. 7B is a schematic diagram illustrating a cross-sectional view of an assembled sensor device (795) according to at least one embodiment of the disclosure, which is formed by fully inserting the connector housing assembly (690) into the sensing assembly (700). The sensing assembly (700) includes a flexible element (750), a force compliant element (703), a plurality of sensing elements (not shown), a PCB (707), and PCB components and integrated circuits (708). Referring to FIG. 7B An axial force is applied to the connector housing assembly to compress the electrical contacts (420) (e.g., springs). In particular embodiments, the housing assembly (690) can be coupled to the sensing assembly (700) at a connection point. For example, the housing assembly (690) can be coupled to the sensing assembly at the connection point by welding, crimping, or gluing.

[0049] FIG. 7BThe design of assembled sensor devices allows sensor designers the option to decouple (high) sealing forces from the internal stack. High sealing forces are applied to separate components. This reduces the risk of failure, but in some products, it also has the potential to increase accuracy due to minimizing internal parasitic forces. Another key benefit is that the seal can be significantly improved due to the increased and stable compression of the seal. Internal components can also potentially be simplified, as they are not load-bearing. Depending on the sensor design, field failures may be reduced due to the minimization of internal forces. Quality and field return can be important metrics for safety-critical sensors. In sensor production lines, connectors, environmental seals, and sensor housings can be received as single components. These components can be assembled by suppliers or on separate machines on the manufacturing floor. This potentially offers opportunities for process optimization and / or cost reduction.

[0050] FIG. 8 This is a schematic diagram illustrating a cross-sectional view of an assembled sensor device (800) according to at least one embodiment of the present disclosure. FIG. 8 In the example, the assembled sensor device (800) includes a connector assembly (804), which includes a connector (801), an O-ring (802), and a solder ring (803). The connector assembly is fully inserted into a housing (805) to form a connector housing assembly (806), such that the O-ring (802) is properly compressed and the solder ring (803) reduces the gap between the housing (805) and the connector (801). The connector assembly (804) and the housing (805) are rigidly connected in the radial direction at a solder position (830) using various methods, including but not limited to (spot) welding, crimping, and gluing. In this embodiment, after the connector assembly (804) is rigidly connected to the housing (805), the connector (801) cannot move axially due to the fixed solder ring (803). FIG. 8 In one example, the connector housing assembly (806) is inserted into a sensing component (807) including a PCB (810), causing the electrical contacts (808) to be compressed. In a specific embodiment, the connector housing assembly (806) is coupled to the sensing component (807) at a connection point (850).

[0051] By decoupling the (high) force required to seal the environment from the (low) force required to electrically connect the connector to the electrical components, both the o-ring and the electrical compression can be controlled more. This will greatly expand the possible tolerances between components, allowing for cost reduction and increased freedom of component selection (e.g., o-rings, springs, etc.). Another benefit is that due to the decoupling of forces, the rigidity of the connector to housing assembly is significantly higher. This can allow for higher installation forces and reduce parasitic effects from harness variations. A second benefit is that FIG. 5 to FIG. 8 The described sensor device will reduce the force towards the EMA, as the connection can mechanically decouple beyond the spring force. Furthermore, the design of the sensor assembly allows for excellent soldering capabilities due to the reduced gap of the solder ring.

[0052] FIG. 9 is a schematic diagram illustrating an isometric cross-sectional view of an assembled sensor device (900) in accordance with at least one embodiment of the present disclosure. The device (900) includes a connector assembly (998) that is inserted into a sensor housing (959) and coupled to a sensing assembly (999).

[0053] In FIG. 9 In the example of FIG. 9, the connector assembly (998) includes a connector (930) and an o-ring (980) that surrounds the body of the connector (930). The connector assembly also includes a solder ring (983). As explained above, an axial force is applied to fully insert the connector assembly (998) into the sensor housing (959) until the o-ring (980) is properly compressed as it transitions to the narrowed portion (986) of the sensor housing (959). When fully inserted, the solder ring (983) will reduce the gap between the sensor housing (959) and the connector (930).

[0054] In particular embodiments, the connector assembly (998) and the sensor housing (959) can be rigidly connected in the radial direction at the solder location (984) using a variety of methods including, but not limited to, (point) soldering, crimping, and gluing. In this embodiment, after the connector assembly (998) and the sensor housing (959) are rigidly connected, a connector housing assembly is formed, where the connector (930) can no longer move axially due to the fixed solder ring (983).

[0055] In the assembled force sensor device (900), the sensing assembly (999) is inserted into the connector housing assembly. In FIG. 9In the example of FIG. 9, the sensing assembly (999) includes a spring element (941), a force compliant element (942), a membrane (991), a plurality of sensing elements (990), and a PCB (992). When the sensing assembly (999) is inserted into the connector housing assembly, the electrical connections (996) of the connector (930) can be coupled to the PCB (992) of the sensing assembly (999). The force compliant element (942) has a central portion (957) and an outer portion including a lug (952).

[0056] In particular embodiments, the flexible spring element (941) has an outer diameter (940) and a central portion (958), where the flexible spring element (941) is curved from the outer diameter (940) to the central portion (957) of the flexible spring element (941). In this embodiment, the central portion (958) of the flexible spring element (941) is aligned with the central portion (957) of the force compliant element (942). In particular embodiments, the flexible spring element (941) is configured to bend in response to a force applied to the outer diameter (940) of the flexible spring element (941) within a range, such that when the force is transmitted from the outer diameter (940) to the central portion (958) of the flexible spring element (941) and applied to the central portion (957) of the force compliant element (942), the outer diameter moves within a space toward the lug (952) until an additional force beyond the range is applied to the outer diameter (940), causing the outer diameter (940) to contact the lug (952), at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing (959). In this example, the contact between the outer diameter (940) of the flexible spring element (941) and the lug (952) of the force compliant element (942) prevents the central portion (958) of the flexible spring element (941) from moving further toward the central portion (957) of the force compliant element (942). FIG. 9

[0057] In particular embodiments, the flexible spring element (941) has an outer diameter (940) and a central portion (958), where the flexible spring element (941) is curved from the outer diameter (940) to the central portion (957) of the flexible spring element (941). In this embodiment, the central portion (958) of the flexible spring element (941) is aligned with the central portion (957) of the force compliant element (942). In particular embodiments, the flexible spring element (941) is configured to bend in response to a force applied to the outer diameter (940) of the flexible spring element (941) within a range, such that when the force is transmitted from the outer diameter (940) to the central portion (958) of the flexible spring element (941) and applied to the central portion (957) of the force compliant element (942), the outer diameter moves within a space toward the lug (952) until an additional force beyond the range is applied to the outer diameter (940), causing the outer diameter (940) to contact the lug (952), at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing (959). In this example, the contact between the outer diameter (940) of the flexible spring element (941) and the lug (952) of the force compliant element (942) prevents the central portion (958) of the flexible spring element (941) from moving further toward the central portion (957) of the force compliant element (942).

[0058] ​The force compliant element (942) deforms in response to the application of force from the central portion (958) of the flexible spring element (941). The deformation in the force compliant element can be measured by the sensing element (990) through the membrane (991) in the force compliant element (942). The sensing element (990) generates one or more signals indicative of the degree to which the force compliant element deformed in response to the application of force from the central portion (958) of the flexible spring element (941). The signals from the sensing element (990) are provided to components of the PCB (992), which in turn provide output to the electrical connections that are transmitted to the connector (930).

[0059] FIG. 10 is a schematic diagram illustrating an isometric cross-sectional view of an assembled sensor device (1000) in accordance with at least one embodiment of the present disclosure. The device (1000) includes a connector assembly (1098) that is inserted into a sensor housing (1059) and coupled to a sensing assembly (1099).

[0060] In FIG. 10 In an example of the sensor device (1000), the connector assembly (1098) includes a connector (1030) and an O-ring (1080) that surrounds the body of the connector (1030). The connector assembly (1098) also includes a metal weld ring (1083). As explained above, an axial force is applied to fully insert the connector assembly (1030) into the sensor housing (1059) until the O-ring (1080) is properly pressed against the crimped portion (1086) of the sensor housing (1059). When fully inserted, the weld ring (1083) will reduce the gap between the sensor housing (1059) and the connector (1030).

[0061] In a particular embodiment, the connector assembly (1098) and the sensor housing (1059) can be rigidly connected in the radial direction at the weld location (1084) using a variety of methods including, but not limited to, (point) welding, crimping, and gluing. In this embodiment, after the connector assembly (1098) and the sensor housing (1059) are rigidly connected, a connector housing assembly is formed, where the connector (1030) can no longer move axially due to the fixed weld ring (1083).

[0062] In the assembled force sensor device (1000), the sensing assembly (1099) is inserted into the connector housing assembly. In FIG. 10In the example of FIG. 10, the sensing assembly (1099) includes a spring element (1041), a force compliant element (1042), a membrane (1091), a plurality of sensing elements (1090), a PCB (1092), and PCB components (1093). When the sensing assembly (1099) is inserted into the connector housing assembly, electrical connections (1094) of the connector (1030) can be coupled to the PCB (1092) of the sensing assembly (1099). The force compliant element (1042) has a central portion (1070) and an outer portion including lugs (1052).

[0063] In particular embodiments, the flexible spring element (1041) has an outer diameter (1040) and a central portion (1071), where the flexible spring element (1041) is bent from the outer diameter (1040) to the central portion (1071) of the flexible spring element (1041). In this embodiment, the central portion (1071) of the flexible spring element (1041) is aligned with the central portion (1070) of the force compliant element (1042). The outer diameter (1040) of the flexible spring element (1041) is spaced apart from the lugs (1052) of the outer portion of the force compliant element (1042) by a space (1050).

[0064] In particular embodiments, the central portion of the flexible spring element can be coupled to the central portion of the force compliant element. In FIG. 10 In the example of FIG. 10, the central portion (1070) of the force compliant element (1042) extends through the central portion (1071) of the flexible spring element (1041). An outer section (1072) of the central portion (1070) of the force compliant element (1042) extends beyond the central portion (1071) of the flexible spring element (1041), and the outer section (1072) of the central portion (1070) of the force compliant element (1042) deforms and covers the central portion (1071) of the flexible spring element (1041). Because the outer section (1072) deforms and covers a portion of the central portion (1071) of the spring element (1041), the outer section (1072) can hold the central portion (1071) of the spring element (1041) in place relative to the central portion (1070) of the force compliant element (1042). In FIG. 10 In the example of FIG. 10, the outer section of the force compliant element is illustrated as being bent inward. However, in particular embodiments, the outer section of the force compliant element can be straight, such that the outer section of the force compliant element does not hold the outer diameter of the flexible spring element in the space.

[0065] During operation, the flexible spring element (1041) is configured to bend in response to a force applied to the outer diameter (1040) of the flexible spring element (1041) within a range of forces such that when the force is transmitted from the outer diameter (1040) of the flexible spring element (1041) to the central portion (1071) of the flexible spring element (1041) and applied to the central portion (1070) of the force compliant element (1042), the outer diameter moves within the space (1050) towards the lug (1052) until additional force beyond the range is applied to the outer diameter (1040) causing the outer diameter (1040) to press against the lug (1052), at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing (1059). In this example, the contact between the outer diameter (1040) of the flexible spring element (1041) and the lug (1052) of the force compliant element (1042) prevents the central portion (1071) of the flexible spring element (1041) from continuing to compress further against the central portion (1070) of the force compliant element (1042).

[0066] The force compliant element (1042) deforms in response to the force applied from the central portion (1071) of the flexible spring element (1041). The deformation in the force compliant element is measured by the sensing element (1090) through the membrane (1091) in the force compliant element (1042). The sensing element (1090) generates one or more signals indicative of the degree to which the force compliant element deforms in response to the force applied from the central portion (1071) of the flexible spring element (1041). The signals from the sensing element (1090) are provided to components of the PCB (1092), which in turn provide outputs that are transmitted to the electrical connections of the connector (1030).

[0067] FIG. 11 is a schematic diagram illustrating an isometric cross-sectional view of an assembled sensor device (1100) in accordance with at least one embodiment of the present disclosure. The device (1100) includes a connector assembly that is inserted into a sensor housing (1159) and coupled to a sensing assembly (1199).

[0068] In FIG. 11 In the example of FIG. 11, the connector assembly (1198) includes a connector (1130) and an O-ring (1180) that surrounds the body of the connector (1130). The connector assembly also includes a metal weld ring (1183). As explained above, an axial force is applied to fully insert the connector assembly (1198) into the sensor housing (1159) until the O-ring (1180) is properly pressed against the crimped portion (1186) of the sensor housing (1159). When fully inserted, the weld ring (1183) will reduce the gap between the sensor housing (1159) and the connector (1130).

[0069] In particular embodiments, the connector assembly (1198) and the sensor housing (1159) can be rigidly connected in the radial direction at the weld location (1184) using a variety of methods including, but not limited to, (spot) welding, crimping, and gluing. In this embodiment, after the connector assembly (1198) and the sensor housing (1159) are rigidly connected, a connector housing assembly is formed, where the connector (1130) can no longer move axially due to the fixed weld ring (1183).

[0070] In the assembled force sensor device (1100), the sensing assembly (1199) is inserted into the connector housing assembly. In this embodiment, the sensing assembly (1199) includes a flexible spring element (1141), a force compliant element (1142), a membrane (1191), a plurality of sensing elements (1190), a PCB (1192), and PCB components (1193). When the sensing assembly (1199) is inserted into the connector housing assembly, the electrical connections (1194) of the connector (1130) can be coupled to the PCB (1192) of the sensing assembly (1199). The force compliant element (1142) has a central portion (1157) and an outer portion including lugs (1152). FIG. 11

[0071] In particular embodiments, the flexible spring element (1141) has an outer diameter (1140) and a central portion (1158), where the flexible spring element (1141) is bent from the outer diameter (1140) to the central portion (1157) of the flexible spring element (1141). In this embodiment, the central portion (1158) of the flexible spring element (1141) is aligned with the central portion (1157) of the force compliant element (1142). The outer diameter (1140) of the flexible spring element (1141) is spaced apart from the lugs (1152) of the outer portion of the force compliant element (1142) by a space (1150). In this embodiment, the outer portion of the force compliant element is illustrated as being bent inwardly. However, in particular embodiments, the outer portion of the force compliant element can be straight, such that the outer portion of the force compliant element does not hold the outer diameter of the flexible spring element in the space. FIG. 11

[0072] In particular embodiments, the central portion (1158) of the flexible spring element (1141) is coupled to the central portion (1157) of the force compliant element (1142). In this embodiment, the outer diameter (1140) of the flexible spring element (1141) is held in the space (1150) by the lugs (1152) of the outer portion of the force compliant element (1142). FIG. 11 ​​In the example of FIG. 11, the sensing assembly (1199) further includes an engagement component (1190) that extends through and couples together the central portion (1158) of the flexible spring element (1141) and the central portion (1157) of the force compliant element (1142). In particular embodiments, a screw (not shown) can be used to secure the engagement component (1190) to the force compliant element (1142).

[0073] During operation, the flexible spring element (1141) is configured to bend in response to a force applied within a range of the outer diameter (1140) of the flexible spring element (1141) such that when the force is transmitted from the outer diameter (1140) to the central portion (1158) of the flexible spring element (1141) and applied to the central portion (1157) of the force compliant element (1142), the outer diameter moves within the space toward the lug (1152) until an additional force beyond the range is applied to the outer diameter (1140) causing the outer diameter (1140) to contact the lug (1152), at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing (1159). In this example, the contact between the outer diameter (1140) of the flexible spring element (1141) and the lug (1152) of the force compliant element (1142) prevents the central portion (1158) of the flexible spring element (1141) from being pressed further toward the central portion (1157) of the force compliant element (1142).

[0074] The force compliant element (1142) deforms in response to the force applied from the central portion (1158) of the flexible spring element (1141). The deformation in the force compliant element can be measured by the sensing element (1190) through the membrane (1191) in the force compliant element (1142). The sensing element (1190) generates one or more signals indicative of the degree to which the force compliant element deformed in response to the application of the force from the central portion (1158) of the flexible spring element (1141). The signals from the sensing element (1190) are provided to components of the PCB (1192), which in turn provide output transmitted to electrical connections of the connector (1130).

[0075] FIG. 12 is a flowchart illustrating an implementation of a method for assembling a force sensor device according to at least one embodiment of the present disclosure, the method including compressing (1202) a sensor housing (e.g., the sensor housing (959) of FIG. 10) with a connector (e.g., the connector (983) of FIG. 9) by inserting the connector into the sensor housing. FIG. 9 FIG. 9 FIG. 9 ​​The environmental seal between the connector (930) and the environmental seal (e.g., FIG. 9 O-ring (980)). In FIG. 12 In the example, the connector has one or more electrical connections. Compression of the environmental seal between the sensor housing and the connector using the (1202) weld ring by inserting the connector into the sensor housing can be performed by pushing the connector until the environmental seal is pressed against the narrowed portion of the sensor housing.

[0076] FIG. 12 The method involves coupling a weld ring (1203) to the sensor housing. Coupling the weld ring (1203) to the sensor housing can be performed by welding, crimping, or gluing.

[0077] FIG. 12 The method also includes using sensing components (e.g., FIG. 9 The sensing component (990) is inserted (1204) into the sensor housing. Inserting the sensing component (1204) into the sensor housing can be done by aligning the sensing component with the sensor housing.

[0078] exist FIG. 12 In the example, the sensing assembly may include a force-compliant element having a central portion and an outer portion. The sensing assembly may also include one or more sensing elements coupled to the central portion of the force-compliant element. FIG. 12 In the example, the force-compliant element deforms in response to a force applied to it, and one or more sensing elements generate one or more signals indicating the degree to which the force-compliant element deforms in response to a force applied to it.

[0079] FIG. 12 The method also includes coupling (1206) the spring element of the connector to the printed circuit board (PCB) of the sensing assembly. FIG. 12 In the example, the PCB is coupled to one or more sensing elements of the sensing assembly. Coupling the spring element of the connector (1206) to the PCB can be performed by pushing the sensing assembly until the spring element of the connector is connected to the PCB of the sensing assembly.

[0080] also, FIG. 12 The method also includes coupling (1208) the sensing component to the sensor housing. Coupling (1208) the sensing component to the sensor housing can be performed by welding, gluing, and crimping.

[0081] As explained above, the weld ring can be used to decouple the (high) force required for the environmental sealing of the sensor device and the (low) force required to electrically connect the connector to the electrical components, so that both the environmental sealing and the electrical compression can be more controlled. This can greatly expand the possible tolerances between components, allowing for reduced costs and increased freedom of component selection (e.g., O-rings, springs, etc.). Another benefit is that the rigidity of the connector to housing assembly can be significantly higher due to the decoupling of forces. This can allow for higher installation forces and reduce parasitic effects from harness variations. Furthermore, the design of the sensor assembly allows for improved weldability due to the reduced gap of the weld ring.

[0082] Advantages and features of the present disclosure can be further described through the following statements:

[0083] 1. A force sensor device comprising a sensor housing and a sensing assembly, the sensing assembly comprising: a force compliant element having a central portion and an outer portion; one or more sensing elements coupled to the central portion of the force compliant element; and a flexible spring element having an outer diameter and a central portion, the flexible spring element bending from the outer diameter to the central portion of the flexible spring element; the central portion of the flexible spring element is aligned with the central portion of the force compliant element; the outer diameter is spaced apart from a ledge of the outer portion of the force compliant element by a space; the flexible spring element is configured to bend in response to a range of forces applied to the outer diameter, such that when the forces are transmitted from the outer diameter of the flexible spring element to the central portion and applied to the central portion of the force compliant element, the outer diameter moves within the space towards the ledge until an additional force beyond the range is applied to the outer diameter, causing the outer diameter to press against the ledge, at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing; the force compliant element deforms in response to the force applied from the central portion of the flexible spring element; and the one or more sensing elements generate one or more signals indicative of the extent to which the force compliant element deforms in response to the force applied from the central portion of the flexible spring element.

[0084] 2. The force sensor device of statement 1, wherein contact between the outer diameter of the flexible spring element and the ledge of the force compliant element prevents the central portion of the flexible spring element from continuing to compress further against the central portion of the force compliant element.

[0085] 3. The force sensor device of statement 1 or 2, wherein the sensing assembly comprises a disc having a first surface coupled to a dedicated interface and a second surface coupled to the outer diameter of the flexible spring element; wherein application of force from the dedicated interface to the first surface of the disc is transferred to the outer diameter of the flexible spring element.

[0086] 4. The force sensor device of any of statements 1-3, wherein an outer section of the force compliant element is bent inward to maintain an outer diameter of the flexible spring element in the space.

[0087] 5. The force sensor device of any of statements 1-4, wherein a central portion of the flexible spring element is coupled to a central portion of the force compliant element.

[0088] 6. The force sensor device of any of statements 1-5, wherein the central portion of the force compliant element extends through the central portion of the flexible spring element.

[0089] 7. The force sensor device of any of statements 1-6, wherein an outer section of the central portion of the force compliant element extends beyond the central portion of the flexible spring element, the outer section of the central portion of the force compliant element deforms and covers the central portion of the flexible spring element.

[0090] 8. The force sensor device of any of statements 1-7, further comprising a joining component that extends through and couples together the central portion of the flexible spring element and the central portion of the force compliant element.

[0091] 9. The force sensor device of any of statements 1-8, further comprising a connector assembly coupled to the sensor housing, the connector assembly comprising: a connector inserted into the sensor housing, the connector comprising one or more spring elements for electrical connection to a PCB, the PCB coupled to the one or more sensing elements; and a weld ring that compresses an environmental seal between the sensor housing and the connector.

[0092] 10. A force sensor device comprising: a sensor housing; a connector inserted in the sensor housing; a weld ring that compresses an environmental seal between the sensor housing and the connector; and a sensing assembly coupled to the sensor housing, the sensing assembly comprising: a force compliant element having a central portion and an outer portion; and one or more sensing elements coupled to the central portion of the force compliant element; the force compliant element deforms in response to a force applied to the force compliant element; and the one or more sensing elements generate one or more signals indicative of an extent to which the force compliant element deforms in response to the force applied to the force compliant element.

[0093] 11. The force sensor device of statement 10, wherein the sensing assembly further comprises: a flexible spring element having an outer diameter and a central portion, the flexible spring element bending from the outer diameter of the flexible spring element to the central portion; the central portion of the flexible spring element is aligned with the central portion of the force compliant element; the outer diameter is spaced apart from the lugs of the outer portion of the force compliant element by a space; the flexible spring element is configured to bend in response to a force applied to the outer diameter within a range, such that when the force is transferred from the outer diameter of the flexible spring element to the central portion and applied to the central portion of the force compliant element, the outer diameter moves within the space toward the lugs until an additional force beyond the range is applied to the outer diameter, causing the outer diameter to press against the lugs, at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing.

[0094] 12. The force sensor device of statement 10 or 11, wherein contact between the outer diameter of the flexible spring element and the lugs of the force compliant element prevents the central portion of the flexible spring element from moving further toward the central portion of the force compliant element.

[0095] 13. The force sensor device of any of statements 10-12, wherein the sensing assembly comprises: a disc having a first surface coupled to a dedicated interface and having a second surface coupled to the outer diameter of the flexible spring element; wherein application of the force from the dedicated interface to the first surface of the disc is transferred to the outer diameter of the flexible spring element.

[0096] 14. The force sensor device of any of statements 10-13, wherein the outer section of the force compliant element bends inward to hold the outer diameter of the flexible spring element in the space.

[0097] 15. The force sensor device of any of statements 10-14, wherein the central portion of the flexible spring element is coupled to the central portion of the force compliant element.

[0098] 16. The force sensor device of any of statements 10-15, wherein the central portion of the force compliant element extends through the central portion of the flexible spring element.

[0099] 17. The force sensor device of any of statements 10-16, wherein an outer section of the central portion of the force compliant element extends beyond the central portion of the flexible spring element, the outer section of the central portion of the force compliant element deforms and covers the central portion of the flexible spring element.

[0100] 18. The force sensor device of any of statements 10-17, further comprising an engagement component extending through and coupling together a central portion of the flexible spring element and a central portion of the force compliant element.

[0101] 19. A method of assembling a force sensor device, the method comprising: compressing an environmental seal between a sensor housing and a connector using a weld ring by inserting the connector into the sensor housing, the connector having one or more electrical connections; coupling the weld ring to the sensor housing; inserting a sensing assembly into the sensor housing, the sensing assembly comprising: a force compliant element having a central portion and an outer portion; and one or more sensing elements coupled to the central portion of the force compliant element; the force compliant element deforming in response to a force applied to the force compliant element; and the one or more sensing elements generating one or more signals indicative of an extent to which the force compliant element has deformed in response to the force applied to the force compliant element; coupling the one or more sensing elements to the one or more electrical connections of the connector; and coupling the sensing assembly to the sensor housing.

[0102] 20. The method of statement 19, wherein the sensing assembly further comprises: a flexible spring element having an outer diameter and a central portion, the flexible spring element bending from the outer diameter to the central portion of the flexible spring element; the central portion of the flexible spring element being aligned with the central portion of the force compliant element; the outer diameter being spaced apart from a ledge of the outer portion of the force compliant element by a space; the flexible spring element being configured to bend in response to a force applied to the outer diameter within a range, such that when the force is transferred from the outer diameter to the central portion of the flexible spring element and applied to the central portion of the force compliant element, the outer diameter moves within the space toward the ledge until an additional force beyond the range is applied to the outer diameter, causing the outer diameter to press against the ledge, at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing.

[0103] One or more embodiments can be described herein with the aid of method steps that utilize the execution of functions and their relationships to one another as illustrated in the diagrams. The boundaries and order of these functional building blocks and method steps have been arbitrarily defined, for the convenience of the description. Alternate boundaries and orders can be defined so long as the same functions and relationships to one another are appropriately performed. Regardless of, and notwithstanding the boundary element formation, such changes and modifications will be

[0104] The flow diagram boundaries and sequence can additionally define the scope of use and still be executed with certain important functions omitted, or with additional functions added to the above described sequences. Accordingly, not only the combinations of functions and steps illustrated are possible, but also other combinations of structures, materials, and / or components can be provided and still be within the scope of the claims. One of ordinary skill in the art will recognize many modifications and variations of the examples described herein that are also within the scope of the present disclosure. Thus, it is intended that the scope of the disclosure should not be limited by the particular illustrative frames of reference described herein.

[0105] While specific combinations of different functions and features of one or more embodiments are expressly disclosed herein, other combinations of these features and functions are also possible. The disclosure expressly encompasses these other combinations.

Claims

1. A force sensor device comprising a sensor housing and a sensing assembly, the sensing assembly comprising: a force compliant element having a central portion and an outer portion; one or more sensing elements coupled to the central portion of the force compliant element; and a flexible spring element having an outer diameter and a central portion, the flexible spring element bending from the outer diameter of the flexible spring element to the central portion of the flexible spring element; the central portion of the flexible spring element being aligned with the central portion of the force compliant element; the outer diameter being spaced apart from a ledge of the outer portion of the force compliant element by a space; the flexible spring element being configured to bend in response to a force applied to the outer diameter within a range, such that when the force is transferred from the outer diameter of the flexible spring element to the central portion and applied to the central portion of the force compliant element, the outer diameter moves within the space toward the ledge until an additional force beyond the range is applied to the outer diameter, causing the outer diameter to press against the ledge, at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing; the force compliant element deforming in response to the application of the force from the central portion of the flexible spring element; and the one or more sensing elements generating one or more signals indicative of the extent to which the force compliant element has deformed in response to the application of the force from the central portion of the flexible spring element. Contact between the outer diameter of the flexible spring element and the ledge of the force compliant element prevents the central portion of the flexible spring element from continuing to compress further against the central portion of the force compliant element.

2. The force sensor device of claim 1, wherein, The sensing assembly comprises a disc having a first surface coupled to a dedicated interface and having a second surface coupled to the outer diameter of the flexible spring element; wherein a force applied to the first surface of the disc from the dedicated interface is transferred to the outer diameter of the flexible spring element.

3. The force sensor apparatus of claim 1, wherein, An outer section of the force compliant element bends inward to retain the outer diameter of the flexible spring element in the space.

4. The force sensor apparatus of claim 1, wherein, The central portion of the flexible spring element is coupled to the central portion of the force compliant element.

5. The force sensor apparatus of claim 1, wherein, The central portion of the force compliant element extends through the central portion of the flexible spring element.

6. The force sensor apparatus of claim 1, wherein, An outer section of the central portion of the force compliant element extends beyond the central portion of the flexible spring element, the outer section of the central portion of the force compliant element deforming and covering the central portion of the flexible spring element.

7. The force sensor device of claim 6, wherein, 8. The force sensor device of claim 1, further comprising a joining component extending through and coupling together the central portion of the flexible spring element and the central portion of the force compliant element.

9. The force sensor device of claim 1, further comprising a connector assembly coupled to the sensor housing, the connector assembly comprising: ​ a connector inserted into the sensor housing, the connector including one or more spring elements for electrical connection to a printed circuit board (PCB) coupled to the one or more sensing elements; and a weld ring compressing an environmental seal between the sensor housing and the connector.

10. A method of assembling a force sensor device, the method comprising: inserting a connector into a sensor housing, the connector having a spring element; inserting a sensing assembly into the sensor housing, the sensing assembly including: a force compliant element having a central portion and an outer portion; and one or more sensing elements coupled to the central portion of the force compliant element and a printed circuit board (PCB); the force compliant element deforming in response to a force applied to the force compliant element; the one or more sensing elements generating one or more signals indicative of an extent to which the force compliant element has deformed in response to the force applied to the force compliant element; and a flexible spring element having an outer diameter and a central portion, the flexible spring element bending from the outer diameter of the flexible spring element to the central portion; the central portion of the flexible spring element aligned with the central portion of the force compliant element; the outer diameter spaced apart from a ledge of the outer portion of the force compliant element by a space; the flexible spring element configured to bend in response to a force applied to the outer diameter within a range, such that when the force is transferred from the outer diameter of the flexible spring element to the central portion and applied to the central portion of the force compliant element, the outer diameter moves within the space toward the ledge until an additional force beyond the range is applied to the outer diameter, causing the outer diameter to press against the ledge, at which point the additional force is applied to the outer portion of the force compliant element and the sensor housing; coupling the spring element of the connector to the printed circuit board (PCB) of the sensing assembly; and coupling the sensing assembly to the sensor housing.

11. The method of claim 10, further comprising: using a weld ring to compress an environmental seal between the sensor housing and the connector; and coupling the weld ring to the sensor housing.

12. The method of claim 10, wherein, Contact between the outer diameter of the flexible spring element and the ledge of the force compliant element prevents the central portion of the flexible spring element from continuing to compress further against the central portion of the force compliant element.

13. The method of claim 10, wherein, The sensing assembly includes a disc having a first surface coupled to a dedicated interface and having a second surface coupled to the outer diameter of the flexible spring element; wherein a force applied to the first surface of the disc from the dedicated interface is transferred to the outer diameter of the flexible spring element.

14. The method of claim 10, wherein, The outer section of the force compliant element bends inward to maintain the outer diameter of the flexible spring element in the space.

15. The method of claim 10, wherein, The central portion of the flexible spring element is coupled to the central portion of the force compliant element.

16. The method of claim 10, wherein, The central portion of the force compliant element extends through the central portion of the flexible spring element.

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