Sensor device for a composite component, base protection device comprising such a sensor device and method for producing a base protection device

Abstract

The invention relates to a sensor device (200) for a composite component, comprising: a planar carrier (210); a plurality of electrically conductive sensor wires (220) arranged on the carrier (210) and associated with respective areas of the carrier (210); and a connection device (230) which is arranged on the carrier (210) and is provided for external electrical connection of all the sensor lines (220), the connection device (230) having a flexible printed circuit board (231) on which a plurality of connection elements for external electrical connection of the sensor lines (220) are located, said connection elements being electrically connected to the sensor lines (220). The invention further relates to an underbody protection device for a motor vehicle having such a sensor device (200) and to a method for producing an underbody protection device.

Description

Technical Field

[0001] The invention relates to a sensor device for a composite component, in particular for an underbody protection device. The invention also relates to an underbody protection device for a motor vehicle, which has such a sensor device and is designed as a composite component, and to a method for producing an underbody protection device. Background Art

[0002] Composite components, in particular so-called underbody protection or chassis protection for motor vehicles, can be equipped with at least one sensor device, which is particularly designed to detect deformations of the composite component caused by an accident, which deformations can also indicate damage to surrounding components or assemblies. The sensor device can have at least one sensor line or the like serving as a deformation sensor. Such a sensor line must be electrically contacted or connected in a suitable manner in order to electrically connect it, for example, to a control unit, which can also be referred to as external electrical contacting.

[0003] DE 10 2017 206 663 A1 describes a protective plate for a battery housing of an electric vehicle, the protective plate being made of plastic, for example. The protective plate has at least one deformation sensor. The deformation sensor comprises a conductive coating applied to the protective plate. The conductive coating is preferably a conductor line extending between a first terminal and a second terminal. The deformation sensor is connected to an evaluation circuit via the first terminal and the second terminal.

[0004] DE 10 2021 106 171.7 describes a composite component with a sensor line, which is preferably designed as a chassis component. A small metal plate electrically connected to the sensor line can be provided at the connection position or connection area of ​​the sensor line. The sensor line is preferably sewn or embroidered on the small metal plate. Summary of the invention

[0005] The object of the present invention is to provide a robust sensor arrangement having a plurality of sensor lines for a composite component, which sensor arrangement allows particularly simple external electrical contacting of the sensor lines.

[0006] This object is achieved by a sensor device according to the invention having the features of claim 1. According to the parallel claims, the invention also relates to an underbody protection device for a motor vehicle, which is designed as a composite component, and to a method for producing the underbody protection device. Advantageous developments and embodiments of the invention follow analogously for all inventive subjects from the dependent claims, the following description of the invention (which explicitly also includes the features described by way of example and optionally), and the drawings.

[0007] The sensor device according to the invention, which may also be referred to as a deformation sensor device, comprises at least the following components:

[0008] - a flat, ie essentially two-dimensional, carrier;

[0009] a plurality of, that is to say at least two or more, electrically conductive sensor lines, which are arranged or laid on a (flat) carrier and are associated with corresponding regions of the carrier, which means in particular that each sensor line is arranged or laid in a different region or section of the carrier; and

[0010] - (single) connecting device arranged on a (surface-type) carrier, the connecting device being configured for external electrical contacting of all sensor lines, wherein the connecting device has a flexible printed circuit board, a plurality of contact elements being located at or on the printed circuit board, the contact elements being electrically connected to the sensor lines, i.e. electrically conductively connected, and being configured for external electrical contacting of the sensor lines.

[0011] On the one hand, in the sensor device according to the invention, a particularly simple external electrical connection of all sensor lines can be achieved by combining the connection locations or connection points at or on the printed circuit board, that is, a connection that is both simple to construct and simple to manufacture. (The external electrical connection of the sensor lines or all sensor lines refers in particular to a plurality of external electrical connections, which is not explicitly distinguished below.) On the other hand, the sensor device according to the invention is also robust, since the printed circuit board is not sensitive to mechanical stresses due to its flexible properties (see below). In addition, the invention has economic advantages and also facilitates process-reliable automation of various manufacturing processes or steps.

[0012] The planar carrier (hereinafter also referred to as carrier) is preferably a planar textile (sensor textile) or a textile planar formation. It is particularly a fiber nonwoven or a fiber nonwoven material, etc. The textile or fiber nonwoven is particularly formed of glass fibers. The carrier can be designed to be relatively thin and have a thickness of only a few tenths of a millimeter.

[0013] The sensor wire can have a diameter of 50 μm to 150 μm. It is preferably a metal sensor wire, in particular a so-called resistance wire. The sensor wire is laid on a carrier in a predetermined route, for example a meandering route, and is fixed in a suitable manner, for example glued or embroidered on the carrier. The sensor wire is provided for acquiring or detecting possible deformations of the composite component, in particular deformations caused by accidents (deformations are usually accompanied by deterioration of the structural integrity), wherein quantification can also be achieved if necessary. This is achieved in particular by detecting the change in resistance caused by the change in length of the sensor wire caused by the deformation. Therefore, the sensor wire acts as a deformation sensor and can therefore also be called a deformation sensor wire. The use of multiple sensor wires can reduce the risk of complete failure of deformation detection. The regional arrangement of the sensor wires can also achieve the positioning of the deformation.

[0014] The connection device is also arranged on the carrier and is preferably fixed to the carrier in a suitable manner, for example by sewing, embroidery or bonding. The connection device can also be called a connection device. The connection device is provided for the external electrical connection of all sensor lines and can therefore also be called a central connection device, which is independent of its positioning on the carrier. (As mentioned above, the external electrical connection of all sensor lines refers in particular to a plurality of external electrical connections.) Preferably, all sensor lines are laid so that their line ends are located on the connection device, i.e. the sensor lines are respectively led out of the connection device and then returned in a loop.

[0015] According to the invention, the connection device is designed as a flexible circuit board or has a flexible circuit board. The flexible circuit board (hereinafter also referred to as a circuit board) is formed by a flexible and / or stretchable insulating material, in particular a plastic film or a textile flat structure, etc., and a conductor line applied thereon or introduced therein as necessary, which is made of a conductive material, in particular copper or a copper alloy. Compared with a rigid circuit board, a flexible circuit board can be deformed without impairing its function, thereby reducing, for example, the mechanical stress that occurs during the production process of the composite component or when placing the auxiliary connection element, which mechanical stress may cause damage (such as fracture and wire disconnection). The flexible circuit board is preferably designed to be rectangular and has a size of not more than 30 mm x 100 mm.

[0016] According to the invention, the (flexible) printed circuit board has a plurality of contact elements which are electrically connected to the sensor lines and which can also be referred to as internal contact elements due to their arrangement in the composite component. These (internal) contact elements are provided as contact locations or connection points in order to make electrical contact with the sensor lines approximately from the outside and in particular with a controller, which is in particular an evaluation and / or control unit. For this purpose, externally placed contact auxiliary elements can be provided, which can also be referred to as external contact elements, which are electrically conductively connected to the (internal) contact elements of the connection device.

[0017] Preferably, two contact elements are provided for each sensor line of the sensor device on the connection device or the circuit board, and in particular the corresponding line ends (sensor line ends) are electrically conductively connected to the contact elements. For example, four sensor lines and eight contact elements are provided. However, it can also be provided that a plurality of sensor lines, in particular all sensor lines, are electrically conductively connected to the same contact element at one of their line ends, and then a common ground connection is made, for example, via the contact element for the relevant sensor lines. In the case of four sensor lines, five contact elements are sufficient.

[0018] The contact elements are preferably arranged in a row on the circuit board. In other words: the contact elements are arranged adjacent to each other so that they are located in a line. Therefore, it is easier to establish external contact, especially when the external contact (i.e., the establishment of external contact) is automatically performed.

[0019] The flexible circuit board preferably has a plurality of separate, that is to say, electrically non-connected conductor lines, which connect the sensor line, in particular its line end, to the contact element in an electrically conductive manner. These conductor lines preferably have a first contact surface and a second contact surface, respectively, at least one line end (sensor line end) being electrically conductively connected to the first contact surface, and the second contact surface being used for external electrical connection. The sensor line or its line end is particularly welded to the first contact surface or is electrically conductively connected to the first contact surface or fixed to the first contact surface in other suitable ways. The second contact surface can be directly designed as a contact element. However, the contact element is preferably constructed or designed as a contact strip or a small metal plate to ensure sufficient connection quality, in particular stable contact resistance. These contact strips are preferably welded to the circuit board, in particular to the second contact surface, or are electrically conductively connected to the second contact surface or fixed to the second contact surface in other suitable ways. The contact strip can have a thickness of a few tenths of a millimeter (strip thickness), for example up to 0.5 mm or even up to 1.0 mm.

[0020] An "electrically conductive connection" (hereinafter also referred to simply as "electrical connection") refers in particular to a galvanic connection between connected electrical components, that is, a mechanical connection that conducts electrical current. The same applies to the expression "conductively connected" (hereinafter also referred to simply as "electrically connected"). "Electrically connected" is understood to be an electrically conductive connection between electrical components that is brought about by suitable connection or connection means. Furthermore, the expressions "conductive connection" or "conductively connected" and "electrically connected", in particular "external electrical connection", refer to both a single connection or connection and a plurality of connections or connections, wherein, for the sake of simplicity, no distinction is sometimes made between the singular and the plural.

[0021] The sensor device according to the invention, which can also be referred to as a sensor arrangement due to the arrangement of a plurality of sensor lines on a carrier, is provided for use in a composite component, in particular in a planar, that is to say essentially two-dimensional, composite component. A composite component is a component made of a plurality of raw materials or materials. A composite component is in particular a component made at least partially of a fiber-reinforced plastic composite material, which can also be referred to as a fiber-reinforced plastic composite component. It is therefore preferably a fiber-reinforced plastic composite component, preferably a thermoplastic fiber-reinforced plastic composite component, which in particular consists of a plurality of layers. Specifically, it is a sandwich component having an inner core layer and two outer cover layers. The sensor device according to the invention can be provided as a prefabricated intermediate product and integrated into the composite component during the manufacture of the composite component, in particular into the layer structure.

[0022] This composite component is preferably designed as an underbody protection device or chassis protection device for a motor vehicle. According to the present invention, this underbody protection device designed as a composite component has at least one sensor device according to the present invention, which is particularly located inside the underbody protection device or integrated into the underbody protection device. The underbody protection device is preferably designed as a shell-shaped sandwich component with a core layer and two cover layers, wherein the sensor device is particularly arranged in one of the cover layers or between the core layer and one of the cover layers. The underbody protection device is particularly designed to protect a power battery installed on a motor vehicle. The sensor device can then be used to detect or acquire deformation of the underbody protection device that endangers the power battery or its battery module.

[0023] The following statements regarding the underbody protection also apply analogously to composite components, in particular flat and / or shell-shaped composite components which are not designed as underbody protection.

[0024] In order to realize the external electrical connection of the sensor line of the sensor device, it is preferred to provide a plurality of external connecting wires, which are electrically conductively connected to the connecting device of the sensor device or the connecting element on the flexible circuit board. The external connecting wire refers to the conductive wire that is not arranged inside the composite component or the bottom protection device. The external connecting wire can be at least partially provided with an insulating portion, such as an insulating varnish or a sheath, and can therefore also be called a connecting cable. The external connecting wire can be at least partially fixed on the composite component or the bottom protection device. Preferably, each connecting element of the connecting device or the circuit board is provided with an external connecting wire. The conductive connection between the external connecting wire and the connecting element of the connecting device or the circuit board of the sensor device can be achieved by means of an auxiliary connecting element placed from the outside, that is, applied or introduced from the outside. Metal screws, rivets, friction welding elements, friction nails, etc. are particularly suitable as auxiliary connecting elements. In addition, a cable terminal or the like can be provided on the wire end (wire end) on the relevant or sensor side of the connecting wire. The wire end (wire end) on the relevant or sensor side of the external connecting wire can also be welded to the connecting element on the flexible circuit board.

[0025] The sensor device is preferably provided with a controller, which is in particular an electrical or electronic evaluation and / or control unit, which is in particular electrically connected to the sensor device by means of or using external connecting lines or is electrically conductively connected to the sensor device.

[0026] The electrical connection of the controller (this means the electrically conductive connection between the controller and the sensor device or the sensor lines of the sensor device via the connecting means) can be made quasi-directly, ie external connecting lines are laid from the connecting device or the flexible printed circuit board to the controller.

[0027] However, it is preferred to set the approximately indirect electrical connection of the controller by means of a multi-connection element or a multi-connector fixed on the bottom protection device, in particular on its inner side, which is preferably designed as a multi-coupler. The multi-connection element is preferably arranged in an area that is not too important for mechanical hazards and media influences. The multi-connection element can be arranged on a protrusion similar to the controller (see below). The fixing of the multi-connection element is carried out, for example, by means of bonding-, screw- or locking- or clip connection. The external connecting line is only laid with the multi-connection element starting from the connecting device or the flexible circuit board. The electrical connection between the multi-connection element and the controller can then be completed via a multi-core cable, such as a flat ribbon cable, which can be designed with at least one plug-in element for connecting to the multi-connection element and / or the controller. The connection cost is thus reduced.

[0028] The controller is preferably arranged on the underbody protection device, in particular in an area that is less critical for mechanical hazards, and is fixed to the underbody protection device in a suitable manner. The fixing is performed, for example, by means of an adhesive, screw or latching or clip connection. It is particularly provided that the controller is arranged at a distance of no more than 200 mm, in particular no more than 100 mm from the connection device of the sensor device or the flexible circuit board, so as to make the external connection lines as short as possible and thus minimize possible interference factors (for the analog signal). The controller is preferably arranged on the inner side (facing away from the road) of the underbody protection device, in particular on a raised portion, which is formed, for example, by means of ribs or as a plateau, in order to avoid or at least reduce possible media influences, in particular the danger caused by the accumulation of water or other media. The controller is preferably arranged in the vicinity of the screw connection point or fixing point of the underbody protection device (this also preferably also applies similarly to the multiple connection elements).

[0029] The method according to the invention for producing an underbody protection device designed as a composite component comprises at least the following steps:

[0030] - producing or generating a layer structure comprising multiple layers (by forming a stack), the layers of which are formed from plastic, fiber-reinforced plastic and / or fiber semi-finished products or fiber semi-finished product slices, wherein the sensor device according to the invention is also introduced into the layer structure, in particular such that the sensor device is located between two layers or within a layer;

[0031] - Pressing the layer structure into an underbody protection device designed as a composite component, wherein the sensor device including the connecting device is integrated, in particular completely integrated, into the composite component or underbody protection device. The sensor device then forms a sensor layer or a deformation sensor layer within the composite component or underbody protection device.

[0032] The plastic used is in particular a thermoplastic. The reinforcing fibers of the fiber-reinforced plastic are in particular glass fibers. The fiber semi-finished product used is preferably a fiber textile, which is in particular made of glass fibers. The fiber semi-finished product or fiber textile can be pre-impregnated with a plastic, in particular a thermoplastic. The same applies to the flat carrier of the sensor device. During the pressing process, which is in particular hot pressing, the layers of the previously produced layer structure are connected to each other in a material-locked and form-locked manner and form the shape or outer shape of the bottom protection device, wherein additional elements (such as ribs, brackets, spacers, protrusions of the controller, etc.) can be molded. The pressing of the layer structure is preferably carried out in a press-fit pressing mold. The size of the bottom protection device can reach 1500mm x2000mm, or even larger, in which the preferred thickness (total thickness) is only 5mm to 10mm.

[0033] The underbody protection device is preferably a shell-shaped sandwich component with an inner core layer and two outer covering layers, wherein the inner core layer is formed in particular from an LFT molded plastic (LFT=long fiber reinforced thermoplastic) and the outer covering layers are formed from a plurality of fiber semi-finished products. Preferably, when forming the stack, the sensor device is arranged between the layers of one of the covering layers and is thus integrated into the relevant covering layer.

[0034] The method of the present invention may further comprise the following steps:

[0035] An external electrical contact is produced or generated for the sensor lines of the sensor device integrated in the composite component by means of external connecting lines which are electrically conductively connected to contact elements on a connecting device or a flexible printed circuit board of the sensor device.

[0036] External electrical connection, that is to say establishment of external electrical connection, can be carried out manually. This electrical connection is preferably carried out automatically, in particular by means of a robot device or the like.

[0037] Usually, the flexible circuit board including the contact elements for external electrical contact is located inside the composite component or the underbody protection device, so that access to the contact elements must be achieved for the external electrical contact. For this purpose, the contact elements located at or on the flexible circuit board can be exposed after pressing and / or contact auxiliary elements are used. Contact auxiliary elements include, for example, metal screws, rivets, friction nails or mandrel elements, which can also be placed from the outside or outside without exposing the contact elements in advance.

[0038] The position of the flexible circuit board integrated into the component, that is to say located inside the composite component or the underbody protection device, is subject to fluctuations caused by manufacturing. In order to find the flexible circuit board and the connection elements arranged thereon, fixed position regulations do not apply. Preferably, at least one magnetic element is arranged at or on the flexible circuit board of the connecting device, which forms a (magnetically detectable) reference point and can be (magnetically) positioned from the outside. Preferably, at least two magnetic elements arranged at or on the flexible circuit board are provided. Positioning and, if necessary, orientation can also be referred to as calibration. Calibration is particularly automatic. After positioning and, if necessary, orientation, all connection elements can be contacted externally without further expenditure, which is particularly automatic.

[0039] The use of magnetic contact strips also makes it possible to locate the contact strips from the outside by means of magnetic detection. If the electrical contact is produced or established without any significant delay after the hot pressing of the layer structure, positioning can also be carried out with the aid of a thermal imaging camera or the like (metal parts cool more slowly than plastic materials). It can also be provided that in the area of ​​the flexible printed circuit board, at least in the area of ​​the contact element, transparent plastic material is used locally, so that visual positioning can be achieved. The above measures can also be used in combination.

[0040] As mentioned above, the contact elements located on or on the flexible printed circuit board can be exposed after pressing, so that free paths are achieved. This exposure can be achieved by a milling process, which is carried out in particular in such a way that after milling, the contact elements are exposed. For this purpose, the measures described above are also helpful in order to determine the area to be exposed or to be milled.

[0041] The method according to the present invention may further comprise the following steps:

[0042] The control unit is fastened to the underbody protection device and an electrically conductive connection (to the sensor device or its connection device) is established or produced by means of external connecting lines and, if necessary, contact points or connection points are sealed or closed.

[0043] Within the scope of the invention, the features described above and the features explained below can be used not only in the respectively indicated feature combination but also in other feature combinations or alone. This also applies to the features shown in the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The present invention is described in detail below with reference to the accompanying drawings in a non-limiting manner. The features shown in the drawings and / or described below, even independently of the specific feature combination, may be general features of the present invention and may further improve the present invention accordingly. In addition, the features of different embodiments or different implementation possibilities may be combined into other embodiments.

[0045] Figure 1 The layer structure of an underbody protection device with an integrated sensor device is shown.

[0046] Figure 2 Shown in Figure 1 A sensor device having a plurality of sensor lines used in an underbody protection device.

[0047] Figure 3 Shown in Figure 2 A connecting device on a sensor device provided for external electrical connection of a sensor line.

[0048] Figure 4 Shows that Figure 3 Flexible circuit boards for connecting devices.

[0049] Figure 5 Show Figure 1 The top portion of the bottom protection device with exposed Figure 3 The contact element of the connecting device.

[0050] Figure 6 Shown fixed at Figure 1 The controller on the bottom protection device is electrically connected to the sensor device by means of an external connecting wire, and the external connecting wire is connected to the connection device according to Figure 5 The exposed contact element is electrically conductively connected.

[0051] Figure 7 and Figure 6 , shows another possible embodiment of an electrically conductive connection of an external connecting line to a contact element of a connecting device.

[0052] Figure 8 A further possible embodiment of the electrical connection of a control unit to a sensor device of an underbody protection device is shown. DETAILED DESCRIPTION

[0053] exist Figure 1 The underbody protection device 100 for a motor vehicle, shown in the exploded view in FIG. 1 , is designed as a multilayer composite component in a sandwich construction and has an inner core layer 110 and two outer cover layers 120 , 130 . The layers 110 , 120 , 130 are connected in a laminated manner in a material-locking manner. The core layer 110 is preferably formed from a thermoplastic molding plastic, such as an LFT molding plastic. The cover layers 120 , 130 are preferably composed of a plurality of fiber semi-finished product layers. A sensor device 200 having a plurality of electrically conductive sensor lines 220 is integrated into the upper cover layer 130 (facing away from the roadway), so that the sensor device is located inside the underbody protection device 100 or inside the relevant cover layer 130. The following description also applies analogously to a composite component equipped with such a sensor device 200 which is not designed as an underbody protection device.

[0054] exist Figure 2 2 shows a sensor device 200 (before integration into the underbody protection device 100). The sensor device 200 has a flat carrier 210, preferably formed of a fiber nonwoven V and in particular of a glass fiber nonwoven, and a plurality of sensor wires 220 arranged on the carrier 210, the flat carrier preferably being formed of a fiber nonwoven V and in particular of a glass fiber nonwoven, the sensor wires being laid in a meandering manner and being respectively associated with a specific area (sensing area) of the carrier 210. Here, only four sensor wires 220 are provided as an example. The sensor device 200 also has a connecting device 230, which is also arranged on the carrier 210 and is used for external electrical connection of all sensor wires 220 (the connecting device 230 can therefore also be referred to as an integrated connecting device). The contour line U indicates the position of the sensor device 200 in the underbody protection device 100. The sensor wires 220 form independent sensing or detection areas in the underbody protection device 100, which are in particular associated with cavities (deformation chambers) located above the underbody protection device 100 and can detect the intrusion of the underbody protection device 100 into these cavities.

[0055] exist Figure 3 2 shows a connection device 230. The connection device 230 has a flexible circuit board 231. A plurality of connection elements 235 for external electrical connection of the sensor line 220 are located at or on the circuit board 231, and the connection elements are electrically connected to the sensor line 220. The connection elements 235 are soldered connection bars or the like. Two connection elements 235 are provided for each sensor line 220, and the connection elements are respectively conductively connected to the line ends (sensor line ends). Therefore, eight connection elements 235 are provided for four sensor lines 220. The connection elements 235 are arranged in a row or along a line. Each connection element 235 forms a connection position or connection point for external electrical connection of the line end, that is, each line end of the sensor line 220 is conductively connected to a corresponding connection element 235.

[0056] The connecting device 230 also has two magnetic elements 236 arranged on the flexible printed circuit board 231 , which form reference points for positioning the connecting device 230 or the contact element 235 in the underbody protection device 100 , as described above.

[0057] exist Figure 42 shows a flexible printed circuit board 231 of a connection device 230. The flexible printed circuit board 231 has a plurality of conductor tracks 232, wherein eight conductor tracks are provided for the exemplary embodiment shown. Each of the conductor tracks 232 has a first, smaller contact surface 233 and a second, larger contact surface 234, which are formed by locally removing a cover layer of the printed circuit board (usually a topcoat, as indicated by the dot pattern). The line ends (sensor line ends) are electrically conductively fixed (in particular soldered) to each first, smaller contact surface 233 (see Figure 3 A contact strip serving as a contact element 235 is welded to each larger second contact surface 234 (see Figure 3 Due to the flexible properties of the circuit board 231 , the contact surfaces 233 , 234 of the conductor tracks 232 can move relative to one another, which contributes to long-term thermal and mechanical stability both during the production of the underbody protection device 100 and during the product's service life.

[0058] The holes 237 enable the flexible printed circuit board 231 to be fixed to the carrier 210, for example, by means of sewing thread or embroidery thread. In addition, during the pressing process (as described above), plastic bridges can be formed through the holes 237. In the illustrated embodiment, the holes 237 (eight holes) are located in the conductor path 232 between the first contact surface 233 and the second contact surface 234. As a result, a plurality of holes 237 can be arranged in a space-saving manner on the printed circuit board 231, in particular on a small or small-area printed circuit board 231.

[0059] exist Figure 5 1 shows a section of an underbody protection device 100, in the interior of which a connecting device 230 of an integrated sensor device 200 is arranged. Contact elements 235 of the connecting device 230 are partially exposed, in particular by a milling process. The exposed contact elements 235 are located on the inner side of the underbody protection device 100 facing away from the roadway. In the section shown, the underbody protection device 100 also has inner ribs 140.

[0060] exist Figure 6 1 shows a control unit 300 for the sensor device 200, which is arranged in a raised position on the inner side of the underbody protection device 100 on the rib 140. The control unit 300 is electrically connected to the integrated sensor device 200 by means of an external connecting line 400. The external connecting line 400 is electrically conductively connected to the exposed contact element 235 of the connecting device 230. The sensor-side line end of the external connecting line 400 (connecting line end) can be soldered or welded to the contact element 235 of the connecting device 230, wherein a contact auxiliary element (see Figure 7). Thus, each sensor line end (line end of sensor line 220) is electrically conductively connected to a connecting line end (line end of connecting line 400) by means of connecting device 230. Preferably, a locally applied seal or closure is also performed by means of a plastic material, a topcoat, etc., covering all contact locations or connection points.

[0061] exist Figure 7 In the illustrated embodiment, the contact element 235 of the connection device 230 is not exposed but hidden inside the underbody protection device 100. The conductive connection between the external connection line 400 and the contact element 235 of the connection device 230 is realized by means of a cable lug 410 and a contact auxiliary element 420. The line end (connection line end) of the connection line 400 is preferably connected to the cable lug 410 in a materially bonded manner, in particular by soldering or welding. The contact auxiliary element 420 is, for example, a metal screw, a rivet, a friction nail or a mandrel element, a friction welding element, etc. The (external) contact auxiliary element 420 is conductively connected to the (internal) contact element 235 in a form-locked and / or materially bonded manner. The line end (connection line end) of the connection line 400 can also be conductively connected to the contact auxiliary element 420 directly, that is, without the cable lug 410, for example by soldering or welding. The closing of the contact point or the connection point can be omitted. Optionally, however, a locally applied seal or closure can also be provided here.

[0062] exist Figure 6 In the illustrated embodiment, the electrical connection of the controller 300 to the sensor device 200 or the sensor line 210 of the sensor device is realized by means of an external connecting line 400 , wherein the external connecting line 400 forms an approximately direct electrical connection, which can also be referred to as a direct electrical connection of the controller 300 .

[0063] exist Figure 8 In the embodiment shown, the controller 300 is connected approximately indirectly by means of a multiple connection element 430 fixed to the underbody protection device 100. This can also be referred to as an indirect or indirect electrical connection of the controller 300. The external connection line 400 is laid from the connection device 230 or the contact element 235 to the multiple connection element 430. Figure 6 Compared to the illustrated embodiment, the connecting device 230 has a different position and orientation in the underbody protection device 100. The conductive connection between the external connecting line 400 and the contact element 235 of the connecting device 230 can be made according to Figure 6 or Figure 7 A multi-core cable 440 is provided for electrical connection between the multi-connection element 430 and the controller 300 .

[0064] List of reference numerals: 100 Bottom protection device (composite component) 110 Nuclear layer

[0065] 120 Covering layer

[0066] 130 Covering layer 140 ribs (raised part)

[0067] 200 Sensor Devices

[0068] 210 sided carrier

[0069] 220 sensor line

[0070] 230 Connecting Devices

[0071] 231 Flexible circuit board

[0072] 232 Conductor lines

[0073] 233 First contact surface

[0074] 234 Second contact surface

[0075] 235 Switching element

[0076] 236 Magnetic Components 237 holes (drilling)

[0077] 300 Controller

[0078] 400 External connection line

[0079] 410 Cable Terminals

[0080] 420 Switch on auxiliary components

[0081] 430 Multiple connection elements 440 Multi-core Cable U-profile

[0082] V fiber nonwoven

Claims

1. A sensor device (200) for a composite component, the sensor device comprising: - a flat carrier (210); - a plurality of electrically conductive sensor wires (220), the sensor wires being arranged on the carrier (210) and being associated with respective areas of the carrier (210); - A connecting device (230), which is arranged on the carrier (210) and is provided for external electrical connection of all sensor lines (220), wherein the connecting device (230) has a flexible circuit board (231), on which a plurality of connection elements (235) are located, which are electrically connected to the sensor lines (220) and are used for external electrical connection of the sensor lines (220).

2. The sensor device (200) according to claim 1, characterized in that Two contact elements (235) are provided for each sensor line (220).

3. The sensor device (200) according to any one of the preceding claims, characterized in that The contact elements (235) are arranged in a row.

4. The sensor device (200) according to any one of the preceding claims, characterized in that The contact element (235) is designed as a welded-on contact strip.

5. The sensor device (200) according to any one of the preceding claims, characterized in that At least one magnetic element (236) is arranged on the flexible printed circuit board (231), and the magnetic element forms a reference point.

6. An underbody protection device (100) for a motor vehicle, which is designed as a composite component and has a sensor device (200) designed according to any one of claims 1 to 5.

7. The bottom protection device (100) according to claim 6, characterized in that: An external connection line (400) is provided for external electrical connection of the sensor line (220), and the external connection line is electrically conductively connected to a contact element (235) on a flexible printed circuit board (231).

8. The bottom protection device (100) according to claim 7, characterized in that: A controller (300) is provided, and the controller is electrically connected to the sensor device (200) via an external connection line (400).

9. The bottom protection device (100) according to claim 8, characterized in that: The controller (300) is arranged on the raised portion (140) on the inner side of the underbody protection device (100).

10. A method for producing an underbody protection device (100) designed as a composite component according to claim 6, the method comprising the following steps: - producing a layer structure comprising multiple layers, the layers of which are formed from plastic, fiber-reinforced plastic and / or fiber semi-finished products, wherein a sensor device (200) designed according to any one of claims 1 to 5 is also introduced into the layer structure; - pressing the layer structure into an underbody protection device (100) designed as a composite component, wherein the sensor device (200) is integrated into the underbody protection device (100).

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