Sensors and their manufacturing methods

Abstract

A method of manufacturing a sensor (1) includes: step a) providing a sensor housing (2) including sensor electronics (5); step b) inserting a negative geometry (9) into an opening in the sensor housing (2) for mounting a sensor interface (3) and / or sensor interface functional elements (3a, 3b, 4), wherein the negative geometry (9) represents the reverse profile of the sensor interface (3) and / or the sensor interface functional elements (3a, 3b, 4); step c) potting the sensor electronics (5) of the sensor (1) with a casting compound (8); step d) curing the casting compound (8); and step e) removing the negative geometry (9) to form a profile (14) in the cured casting compound (8) that maps the geometry of the sensor interface (3) and / or the sensor interface functional elements (3a, 3b, 4).

Description

Technical Field

[0001] This invention relates to a method for manufacturing a sensor and the sensor itself. Background Technology

[0002] Sensors are critical components in a wide range of applications, including industrial automation, automotive systems, and consumer electronics. The performance and reliability of these sensors depend heavily on the accuracy and stability of their internal components, particularly sensor electronics and sensor interface functional elements.

[0003] Traditional methods of manufacturing sensors often involve complex assembly processes, which can lead to misalignment and instability of sensor interface functional components. These issues can reduce sensor accuracy and reliability, which are critical parameters for high-performance applications. Furthermore, traditional methods may require significant manual labor and complex tooling, increasing production costs and time.

[0004] In the existing technology, the challenge is not only cost-effective production, but also the precise alignment and secure connection of the sensor interface functional elements in the sensor housing.

[0005] In particular, the small sensor size and narrow cross-section present challenges in accommodating components such as sensor electronics, as well as in the assembly or casting process. Therefore, the need for additional space within the sensor to address these issues remains unmet. Furthermore, achieving precise alignment of the cylindrical sensor housing is difficult, leading to larger tolerances and consequently reduced quality. Using an internal housing reduces the contact surface between the potting compound and the sleeve, causing the sensor electronics to become loose. Summary of the Invention

[0006] Therefore, the object of the present invention is to provide a method for manufacturing a sensor to ensure the precise alignment and secure connection of the sensor interface functional elements within the sensor housing.

[0007] Another objective of this invention is to simplify the sensor assembly process.

[0008] Another objective of this invention is to improve the stability and reliability of sensor components.

[0009] Another object of the present invention is to provide a universal manufacturing method that can adapt to various types of sensor interface functional elements and sensor designs.

[0010] These and other issues are addressed through the subject matters of the accompanying independent claims.

[0011] This invention addresses these objectives by introducing a novel method for manufacturing sensors that ensures precise alignment and secure connection of sensor interface functional elements within the sensor housing. This method involves creating precise profiles in a casting compound using negative geometry, which are then used to securely hold the sensor interface functional elements. By employing negative geometry technology, this method further reduces the need for complex tooling and extensive manual labor. By simplifying the assembly process and improving the stability of sensor components, this invention aims to improve the overall performance and reliability of sensors while reducing manufacturing complexity and cost.

[0012] In particular, the present invention offers several advantages. Due to space constraints within the internal housing, connecting pins partially covered by the sleeve must be soldered to the PCB. By using the "negative geometry" concept of the present invention, components can be pre-assembled and then inserted. When using this negative geometry, the grounding wire can be positioned below the HMI. In prior art internal housings, foil must be cut for this purpose, which adds extra effort to positioning the foil and may impair functionality. Furthermore, there is a risk of damaging the grounding wire during assembly with the internal housing. The narrow gap with the internal housing prevents the potting process from being completed in one step, increasing process time and the risk of air inclusions. Therefore, the additional space gained by the present invention can be advantageously used, at least in part, for designing HMI control elements, thereby improving assembly and durability.

[0013] Detailed description of the invention The above-mentioned objectives of the present invention are achieved by a method for manufacturing a sensor according to the first aspect of the present invention and a sensor according to the second aspect of the present invention.

[0014] Preferred embodiments may be derived from the dependent claims, and, in addition, may be derived from the following description, specifically including the various embodiments covered and described in the appended claims.

[0015] The embodiments, features, and combinations thereof described herein in conjunction with the features given in the appended claims, as well as any combination of features mentioned and described in conjunction with the embodiments, shall be deemed to be disclosed herein, but shall at least be considered derivable by those skilled in the art.

[0016] Furthermore, each feature and combination of features used in the claims and in the description below may be independent of the respective subject matter of the claims, independent of claim dependencies and subsequent references, and independent of the category of use and request of the features in the claims. For example, in any combination selected from one or more claims, one or more embodiments as described below and / or one or more embodiments selected from the accompanying drawings may be contemplated.

[0017] The manufacturing method according to the first aspect of the present invention advantageously solves the above-mentioned problems. The method includes at least the following steps: Step a) Provide a sensor housing, including sensor electronics; Step b) Insert the negative geometry into the opening of the sensor housing, the opening being used to mount the sensor interface and / or sensor interface functional elements, wherein the negative geometry represents the reverse profile of the sensor interface and / or the sensor interface functional elements; Step c) Encapsulate the sensor electronics of the sensor with a casting compound; Step d) Curing the casting compound; Step e) Remove the negative geometry, wherein a contour is formed in the cured casting compound, the contour mapping the geometry of the sensor interface and / or sensor interface functional elements.

[0018] As used herein, the term "sensor housing" preferably refers to a structure designed to house or enclose sensor electronics. Sensor housings may also be provided in the form of sensor sleeves. Sensor housings can be single-piece or multi-piece structures, providing design and assembly flexibility. Sensor housings or sensor sleeves ensure that the internal sensor components are protected and kept stable.

[0019] The term "negative geometry" as used herein preferably refers to a form or shape, more preferably a solid form or shape, that represents the reverse profile of the intended sensor interface functional elements. During manufacturing, this negative geometry is inserted into an opening in the sensor housing. It serves as a mold or template, creating a precise profile in the casting compound that securely holds the sensor interface functional elements in place. By using negative geometry, this method ensures precise alignment and secure connection of the sensor interface functional elements within the sensor housing.

[0020] In an advantageous embodiment, the casting compound may be translucent, which advantageously allows light to pass through, making it possible to include a viewing window for a status indicator.

[0021] The negative geometry can take various forms suitable for implementing the present invention. For example, the negative geometry can be provided in the form of a plug. This plug is inserted into an opening in the sensor housing during manufacturing.

[0022] As used herein, the term "sensor interface" preferably refers to a component or system that facilitates communication between a sensor and other devices, systems, or users, enabling the sensor to transmit data and / or receive commands. The sensor interface may include various types of sensor interface functional elements, such as structured sensor interface functional elements like frame elements, connectors, covers, or other attachment features; and / or the sensor interface may include other sensor interface functional elements, such as sensor interface display elements, for example, light guides or 7-segment displays, to display information to the user; and / or the sensor interface may include additional sensor interface functional elements, such as sensor interface setting elements capable of adjusting or inputting sensor settings, for example, rotary knobs, buttons, and other similar controls. In particular, the sensor interface enables the sensor to communicate with or integrate into different environments. Specifically, the sensor interface may be in the form of a human-machine interface, allowing the user to set the sensor and / or display information to the user.

[0023] As used herein, the term "sensor interface functional element" preferably refers to a specific part or feature of a sensor interface that performs different functions, such as signal processing, data conversion, or user interaction. For example, a light guide, display, rotary element, rotary actuator, or frame holding said element can be considered a sensor interface functional element. A light guide can be used to direct light to the sensor, while a rotary actuator or rotary element can be used to adjust settings or input data. These elements can together form a sensor interface.

[0024] As used herein, the term "casting compound" preferably refers to a material used to encapsulate and protect sensor electronics within a sensor housing. This compound is typically a liquid or semi-liquid substance that hardens or solidifies over time to form a solid protective layer. The casting compound ensures the stability and durability of the sensor components by providing mechanical support and protecting them from environmental factors such as moisture, dust, and mechanical stress. Preferably, the casting compound is a potting resin, ideally suited for creating robust and reliable encapsulations for sensor electronics. For example, epoxy casting resins can be used, with the option of adding suitable mineral fillers.

[0025] The term "geometry mapping" as used herein refers to the process of creating a profile in the cured casting compound that corresponds to at least a portion of the contact surfaces of the sensor interface functional elements. This mapping ensures that the resulting profile accurately reflects the necessary portions of the sensor interface functional element's geometry for secure connection and alignment, rather than replicating the entire profile of the entire element. This precise mapping is crucial for maintaining the stability and functionality of the sensor by ensuring that the sensor interface functional elements are correctly positioned and held in place.

[0026] As used herein, the term "removal" preferably refers to the process of extracting or removing negative geometry from the cured casting compound. The removal process ensures that the sensor interface and / or sensor interface functional elements can be safely and accurately positioned within the sensor housing.

[0027] It should be noted that the steps above do not necessarily need to be performed in the given order. The steps provided can be performed in any other suitable order.

[0028] However, the order given above can be applied to specific variations of the method. For example, removal of negative geometry can be performed after the casting compound has been cured.

[0029] The sensor according to a second aspect of the invention also advantageously solves the above-mentioned problems. The sensor includes a sensor interface and / or sensor interface functional elements maintained by a contour formed by a cured casting compound.

[0030] The sensor according to the invention is therefore preferably manufactured using the method according to the first aspect of the invention. Due to the unique properties of the casting compound, a person skilled in the art can immediately distinguish sensors manufactured using the method of the invention. For example, when the sensor is cut open, the specific contours and features formed in the cured casting compound are clearly visible. The contours of at least a portion of the contact surfaces of these mapping sensor interface functional elements are unique and indicate the manufacturing process of the invention. This visibility allows for direct identification of sensors produced by this method, as the precise and secure connection of the sensor interface functional elements within the sensor housing is readily apparent from the appearance of the casting compound.

[0031] In this application, terms such as “lateral” or “laterally,” “rear,” “front,” “upper,” “lower,” “bottom,” “relative,” “inner,” “outer,” etc., describe the position of a first object relative to another object, preferably referring to the relative position of each part or object relative to its fully mounted position, for its intended use.

[0032] Those skilled in the art will immediately recognize that the features, embodiments, effects, or advantages described herein in conjunction with the sensors of the present invention can also be features, embodiments, effects, or advantages of the methods of the present invention, and vice versa.

[0033] In an advantageous embodiment of the method of the invention, particularly in step f), a first sensor interface functional element of the sensor interface is inserted, preferably, a structured sensor interface functional element, into the outline of the cured casting compound.

[0034] The advantage of this approach is that it ensures the precise and secure placement of the first sensor interface functional element within the sensor housing. The contour formed in the casting compound is specifically designed to match at least a portion of the contact surface of the sensor interface functional element, providing a stable and accurate fit.

[0035] In another advantageous embodiment of the method of the invention, particularly in step g), at least one additional sensor interface functional element of the sensor interface, preferably a sensor interface display element (3a) or a sensor interface actuation element, especially a rotation element (3b), is inserted into the outline of the cured casting compound and / or the first sensor interface functional element of the sensor interface.

[0036] The advantages of this embodiment extend the applicability of the invention to multiple sensor interface functional elements. In particular, this embodiment allows for a modular approach to sensor design. By enabling the insertion of additional sensor interface functional elements into existing profiles or the first sensor interface functional element, the sensor can be easily customized or upgraded. This modularity provides the flexibility to adapt the sensor to different applications or needs without requiring a complete redesign. Furthermore, inserting additional sensor interface functional elements into the profile of the cured casting compound or into the first sensor interface functional element ensures a secure and precise fit. This integration improves the stability and reliability of the sensor because all components are firmly secured in place, reducing the risk of misalignment or displacement.

[0037] In another advantageous embodiment of the method of the invention, particularly in step e), and / or the sensor of the invention that forms a profile in the casting compound includes forming at least one undercut.

[0038] This is advantageous because the undercut significantly enhances the secure connection of the sensor interface functional elements within the sensor housing. The undercut provides a mechanical interlock that prevents the sensor interface functional elements from moving or falling off, even under mechanical stress or vibration. This ensures that the sensor interface functional elements remain precisely aligned and firmly held in place, which is crucial for maintaining the accuracy and reliability of the sensor.

[0039] In other words, the undercut profile means that sensor interface functional elements can be more robustly integrated into the sensor housing. The undercut allows for the use of fastening elements, such as latches, which can engage with the undercut to provide a detachable or non-detachable connection. In this respect, the sensor interface functional elements may include fastening elements configured to engage with the undercut of the profile.

[0040] More specifically, if a reverse profile with elastic properties is used, such as an elastic silicone plug, the silicone plug can be easily removed from the cured casting resin despite undercutting due to the elasticity and non-adhesive effect of the surface, allowing for multiple uses and thus reducing costs. Undercutting, on the other hand, makes the corresponding injection-molded parts difficult or impossible to demold, increasing complexity and part cost.

[0041] In another advantageous embodiment of the sensor and / or method of the present invention, in particular, step f) inserts the first sensor interface functional element into the contour, and / or step g) inserts at least one additional sensor interface functional element into at least one first sensor interface functional element, the first sensor interface functional element and / or at least one additional sensor interface functional element, respectively connected to the contour.

[0042] This insertion can be achieved in various ways known to those skilled in the art. Preferably, the insertion includes engagement of the respective sensor interface functional element with the undercut. In particular, the sensor interface functional element includes a respective fastening element for engagement with at least one undercut. Specifically, the sensor interface functional element may include a hook as a fastening element to secure it in the undercut. This engagement ensures that the sensor interface functional element is firmly fixed in place, preventing any movement or displacement. When the sensor interface functional element is pressed into place, it preferably engages with the undercut via the fastening element, thereby effectively locking the sensor interface functional element and preventing it from falling out.

[0043] Accordingly, in another preferred embodiment of the method and / or the sensor of the present invention, connecting the first sensor interface functional element to the contour and / or connecting the at least one sensor interface functional element to the contour includes at least one fixing element for fastening the sensor interface, in particular at least one snap-fit ​​element, to the undercut of the first contour.

[0044] In another advantageous embodiment of the method of the invention, particularly step e), and / or in another advantageous embodiment of the sensor of the invention that removes negative geometry, the negative geometry is melted or decomposed.

[0045] This is advantageous because it allows for the clean and precise removal of negative geometry without damaging or interfering with the cured casting compound. This method ensures that the contour formed in the casting compound remains intact and accurately reflects the intended geometry of the sensor interface functional elements. In particular, plug-type negative geometry provides a straightforward and efficient approach. The plug is easily inserted into the sensor housing and can be reused simply by removing it after the casting compound has cured. The reusability of this plug reduces material costs and simplifies the manufacturing process.

[0046] In another advantageous embodiment of the method and / or the sensor of the present invention, the first sensor interface functional element is a sealing element, wherein step f) inserting the first sensor interface functional element into the contour of the cured casting compound includes the step of inserting the sealing element into the contour.

[0047] This sealing element advantageously provides an additional barrier against environmental factors such as moisture, dust, and contaminants. This protection is crucial for maintaining the integrity and performance of the sensor under harsh or variable conditions.

[0048] More importantly, the sealing element itself can form a profile, so the negative geometry represents the reverse profile of the sealing element of the sensor interface functional element.

[0049] In another preferred embodiment of the method and / or the sensor of the present invention, the profile includes at least one undercut designed to receive a fastening element of the sensor interface functional element.

[0050] This is particularly advantageous because including at least one undercut in the profile significantly enhances the secure connection of the sensor interface functional elements within the sensor housing. The undercut can be specifically designed as a fastening element receiving the sensor interface functional elements, such as a latch or similar locking mechanism. This design ensures that the sensor interface functional elements are firmly in place, preventing movement or displacement during operation.

[0051] In another preferred embodiment of the method and / or sensor of the present invention, the sensor interface functional element includes at least one fastening element, preferably a snap-fit ​​element, especially a hook, designed to connect the sensor interface functional element to the undercut of the contour.

[0052] Using snap hooks as fastening elements simplifies the assembly process, allowing sensor interface components to be quickly and easily inserted into the sensor housing. This reduces the need for additional tools or complex assembly processes, thereby simplifying production and lowering manufacturing costs. Furthermore, the snap hook design allows for both detachable and non-detachable connections, providing flexibility in sensor assembly and maintenance.

[0053] In another advantageous embodiment of the method and / or the sensor of the present invention, the undercut is designed to at least partially surround an opening around the sensor housing for receiving the sensor interface functional elements.

[0054] Of particular advantage is that when the undercut is designed to at least partially surround the opening of the sensor housing to receive the sensor interface functional elements, the secure connection and stability of the sensor interface functional elements are significantly enhanced. By partially surrounding the opening, the undercut provides a robust mechanical interlock, ensuring that the sensor interface functional elements are firmly secured in place. This design minimizes the risk of movement or misalignment of the sensor interface functional elements during operation, which is crucial for maintaining the accuracy and reliability of the sensor.

[0055] In another advantageous embodiment of the method and / or the sensor of the present invention, the sensor interface functional element includes a first sensor interface functional element and at least one additional sensor interface functional element, wherein, preferably, the first sensor interface functional element is a sealing element, and more preferably, the sealing element is made of an elastomer.

[0056] This configuration provides enhanced sealing capabilities, ensuring the sensor is unaffected by environmental factors such as moisture and dust. The use of elastomers in the sealing elements offers excellent flexibility and durability, contributing to the sensor's lifespan and reliability. Furthermore, the presence of multiple sensor interface functional elements allows for safer and more stable connections, further enhancing the overall performance of the sensor.

[0057] In another advantageous embodiment of the method and / or sensor of the present invention, the first sensor interface functional element, particularly in the form of a sensor interface functional element seal, includes at least one fastening element for connecting the sensor interface functional element seal to the undercut of the profile, wherein, most preferably, the at least one additional sensor interface functional element is held by the first sensor interface functional element.

[0058] This design ensures a secure and stable connection between the sealing element and the sensor housing, thereby improving the overall integrity of the sensor. Furthermore, this configuration allows the first sensor interface functional element to retain at least one additional sensor interface functional element. This arrangement not only simplifies the assembly process but also improves sealing efficiency. The presence of the fastening element ensures that the sealing element is firmly secured in place, while the additional sensor interface functional element contributes to a tighter seal, providing superior protection against environmental factors such as moisture and dust.

[0059] In another advantageous embodiment, at least two additional sensor interface functional elements are inserted into the sealing element, such as light guides and rotary actuators, rotating elements, etc., which are held in place by the first sensor interface functional element, i.e., the sealing element. This arrangement not only simplifies the assembly process but also improves sealing efficiency. The presence of the fastening element ensures that the sealing element is securely fixed in place, while the additional sensor interface functional elements contribute to achieving a tighter seal.

[0060] In another advantageous embodiment of the method and / or sensor of the present invention, the sensor interface functional element is configured such that the additional sensor interface functional element is held by the interface sealing element and the sensor interface functional element is sealed, in particular, the fastening element of the interface sealing element (if present) is pressed into or against the undercut.

[0061] This configuration offers several advantages. First, it ensures a safer and more stable connection between the sensor interface functional elements and the sensor housing. By pressing the sealing element into the undercut, the additional sensor interface functional elements improve the sealing effect, providing excellent protection against environmental factors such as moisture and dust. This not only improves the overall durability and reliability of the sensor but also simplifies the assembly process. The additional pressure applied by the extra sensor interface functional elements ensures that the sealing element remains secure, reducing the risk of displacement or leakage. Therefore, this embodiment significantly improves the sensor's performance and lifespan, making it more robust and effective for a variety of applications.

[0062] All embodiments of the present invention have the advantage of ensuring precise alignment and secure connection of the sensor interface functional elements within the sensor housing. This precision improves the overall performance and reliability of the sensor, which is crucial for high-performance applications.

[0063] The sensor according to the invention can be advantageously used for detecting sensor signals, preferably in component manufacturing, mechanical and plant engineering, automotive manufacturing, mobile devices, storage and conveying technologies, the packaging industry, and factory and process automation. The sensor can be any type of sensor, but is preferably a capacitive sensor due to its sensitivity and accuracy, making it highly suitable for these applications.

[0064] In particular, using a reverse profile, such as a plug, instead of an HMI housing solves several problems and offers the following advantages: By employing a reverse profile, the annular cross-section of the HMI housing is eliminated, increasing the effective cross-section for potting and simplifying the manufacturing process. This reduces potting process time while improving quality by reducing air bubbles in the potting compound, which primarily form in narrow channels.

[0065] Positioning the HMI housing requires a complex and tolerance-prone device. Furthermore, there is a risk of incorrect insertion into asymmetrical HMI housings. By using a reverse profile, this device is no longer needed, and the HMI profile position can be repeated due to the gapless fit of the plug within the sleeve.

[0066] When the HMI housing is inserted into the sleeve, the sealing lip of the HMI housing can be sheared at the window of the sleeve. When passing through the sealing lip of the HMI housing, additional steps are required in the internal geometry of the sleeve. Furthermore, the sealing function requires high surface quality. The plug and negative geometry of this invention reduce the corresponding manufacturing cost of the sleeve.

[0067] Eliminating the housing wall thickness between the HMI and electronic components creates more space for the HMI components.

[0068] To ensure the sensor functions properly without interference, grounding is required, which involves welding the grounding braid to the sleeve. The advantage of this invention is that it eliminates the need for an HMI housing, allowing the full space to be used to position the previously extremely compact grounding weld. This increases the difficulty of manufacturing the assembly for positioning the foil. Using a plug allows the grounding braid to be positioned freely.

[0069] Especially in the case of cylindrical designs, as described in this article, an undercut can be formed on the inner contour of the sleeve to prevent the HMI cover from falling off. Forming such an undercut in the production of (flat) plastic housings is very complex due to the injection molding process. It typically requires specific tools, which are easily damaged. Attached Figure Description

[0070] The invention will be described in further detail with reference to the accompanying drawings, from which further features, embodiments, and advantages can be obtained, wherein: Figure 1A A top view of a cylindrical sensor according to a first embodiment of the present invention is shown; Figure 1B A schematic cross-sectional view of a cylindrical sensor according to the prior art is shown; Figure 2A and Figure 2B Based on a cross-section of the cylindrical sensor of the present invention according to a first embodiment, two representative steps in the manufacturing method of the present invention are depicted. Figure 2C Showing Figure 2B Enlarged detail image; Figure 3A A schematic cross-sectional view of a rectangular sensor in the prior art is shown; Figure 3B A schematic cross-sectional view of a rectangular sensor interface according to an embodiment of the second aspect is shown; Figure 4A and Figure 4B A schematic cross-sectional view of the third embodiment of the invention is shown from two different perspectives. Detailed Implementation

[0071] The features of the invention disclosed in this specification, claims and / or drawings may be materials used to implement the invention in various forms.

[0072] In the embodiments shown in the accompanying drawings, elements with similar or identical functions are designated by similar reference numerals. It should be noted that these figures may not be suitable for scaling relative to each other.

[0073] Figure 1A A schematic top view of the sensor provided by the present invention is shown. The sensor includes a sensor housing 2 that surrounds the sensor components and provides structural support. A sensor interface 3 is located within the housing and serves as the main connection point for external components and user actuation or setting. A first sensor interface functional element 4, acting as a sealing element, is shown integrated into the sensor interface 3 to ensure a secure and tight seal. Furthermore, the figure also shows other sensor interface functional elements 3a and 3b, including a display element and an operating element, such as a light guide 3a and a rotating element 3b connected to the sensor interface 3.

[0074] Figure 1B A schematic cross-sectional view of a sensor provided by the prior art is shown. The sensor housing 2 contains the sensor electronics 5. The sensor interface 3 is integrated within the housing as a connection point for external components. A first sensor interface functional element 4 functions as a sealing element, positioned to ensure a secure seal within the sensor interface 3. Additional sensor interface functional elements 3a and 3b are also shown; these can be any suitable display or operating elements, such as a light guide 3a or a rotating element 3b, shown as connected to the sensor interface 3. In the prior art, the HMI housing 21 is a separate component that must be manufactured, inserted, and assembled independently. This additional HMI housing 21 surrounds the human-machine interface components 3a, 3b, and 4 of the sensor interface 3. The sensor electronics 5 is protected by foil 6 and includes a grounding braid 7 to ensure proper electrical grounding. The sensor electronics 5 is housed within the sensor housing 2, providing additional protection and stability. The sensor interface 3 is disposed within an opening in the sensor housing 2. This prior art structure highlights its complexity and requires multiple independent manufacturing and assembly steps, particularly for the HMI housing 21, which must be handled separately.

[0075] Figures 2A, 2B, and 2C show cross-sections of the sensor of the present invention according to a first embodiment, illustrating... Figure 2A The two typical steps in the manufacturing method of the invention shown in Figure 2B. More specifically, Figure 2AThe sensor is shown after step b) in which the negative geometry 9 is inserted into the opening of the sensor housing 2. The negative geometry 9 is depicted as a plug, representing the reverse profile of the sensor interface 3. This step is crucial for forming the final form of the sensor interface. Specifically, according to the method of the invention, in order to manufacture the sensor, in step a), a sensor housing 2 is provided, including sensor electronics 5. Then in step b), the negative geometry 9 is inserted into the opening of the sensor housing 2 for mounting the sensor interface 3. Thus, the negative geometry 9 represents the reverse profile 14 of the sensor interface 3, specifically as follows: Figure 2C As shown by dashed lines.

[0076] With the plug 9 inserted in the appropriate position, in step c), the sensor electronics 5 of the sensor 1 is potted with a casting compound 8, which is cured in step d) of the method of the present invention.

[0077] Figure 2B shows the result after step e) removing the negative geometry 9, revealing the opening with contour 14 (shown as the dashed line in Figure 2C) formed in the cured casting compound 8. This contour 14 maps the geometry of the sensor interface 3, and in particular the geometry of the sensor interface functional element 4. Figure 2B The results of subsequent steps f) and g) are also shown, wherein the first sensor interface functional element 4 is inserted into the profile 14 in the form of a sealing element, and then additional sensor interface functional elements 3a and 3b, here in the form of a light guide 3a and a rotation element 3b, a display element and an operating element, are inserted into the first sensor interface functional element 4, i.e., the sealing element.

[0078] Figure 3A provides a detailed cross-sectional view of sensor interface 3 according to yet another embodiment of the prior art, and Figure 3B A corresponding embodiment of the sensor of the present invention is shown, here being a rectangular sensor.

[0079] Figures 3A and 3B show a sensor interface 3, which includes a first sensor interface functional element 4 in the form of a sealing element 4, and two other sensor interface functional elements 3b in the form of two adjacent rotating elements.

[0080] Figure 3A The sensor interface 3 is shown, and the housing 2 is manufactured using a casting mold according to existing technology. Therefore, the undercut 15 shown is difficult to manufacture; it is specifically designed to receive the fastening element 16, here in the form of a hook 16 for the sealing element 4 of the sensor interface functional element 4. The undercut 15 provides a secure anchoring point, ensuring that the sensor interface functional element 3 is firmly fixed in place.

[0081] Figure 3BThe invention is described in further detail. Here, the casting material 8 is the result after the negative geometry 9 has been removed in step e), showing the formation of contour 14 (according to...) in the cured casting compound 8. Figure 2C The opening (shown by the dashed line in the diagram) is mapped to the geometry of the sensor interface 3, and in particular the geometry of the sensor interface functional element 4. Figure 3B The results of subsequent steps f) and g) are also shown, wherein the first sensor interface functional element 4 in the form of a sealing element is inserted into the profile 14, and then an additional sensor interface functional element 3b (here an operating element in the form of a rotating element 3b) is inserted into the first sensor interface functional element 4, i.e., the sealing element.

[0082] This specific mechanism in Figure 4A and Figure 4B The figures are shown most clearly. These figures illustrate the detailed process of how the hook element 16 is pushed into the undercut 15 of the contour 14 formed by the cured casting compound 8.

[0083] Figure 4A The initial state of the first additional sensor interface functional element 3a inserted as a sealing element into the first sensor interface functional element 4 is shown. The sealing element 4 is already located within the outline 14 of the cured casting compound 8. Figure 4A The diagram illustrates the insertion of a second additional sensor interface functional element 3b into a first sensor interface functional element 4. When the second additional sensor interface functional element 3b is inserted, it applies a force (F) to the first sensor interface functional element 4, specifically to the latch element 16. This force (is caused by…) Figure 4A (As shown by the arrow in Figure 4B) Push the hook element 16 into the undercut 15 of the profile 14 (e.g., in...) Figure 4A (Most clearly seen in Figure 4B) ensuring a secure and stable connection. Figure 4A shows the final state where both additional sensor interface functional elements 3a and 3b are fully inserted into the first sensor interface functional element 4, forming sensor interface 3. The force applied by the second additional sensor interface functional element 3b firmly presses the hook element 16 into the undercut 15, improving the sealing effect and stability of the connection. This mechanism ensures that sensor interface functional elements 3a, 3b, and 4 are all securely fixed in place, thereby providing excellent environmental protection capabilities and improving the overall reliability and performance of the sensor.

[0084] The embodiments in the accompanying drawings may relate to preferred embodiments, and all elements and features described in connection with the embodiments may be used as appropriate in conjunction with any other embodiments and features discussed herein, particularly in relation to any other embodiments further discussed above.

[0085] Reference list of numbers 2 Sensor Housing 21 HMI housing 3 sensor interfaces 3 a, 3 b Additional sensor interface functional elements, operating elements 4. First sensor interface functional component, sealed 5 Sensor Electronics 6 foils 7 Grounding braid 8 Casting Compound 9 negative geometry, plug 11 magnets 12-Card 14 outlines 15 bottom cut 16 Fastening components, hook components

Claims

1. A method for manufacturing a sensor (1), characterized in that, include: Step a) Provide a sensor housing (2), including sensor electronics (5); Step b) Insert the negative geometry (9) into the opening of the sensor housing (2), the opening being used to install the sensor interface (3) and / or sensor interface functional elements (3a, 3b, 4), wherein the negative geometry (9) represents the reverse profile of the sensor interface (3) and / or the sensor interface functional elements (3a, 3b, 4); Step c) Encapsulate the sensor electronics (5) of the sensor (1) with the casting compound (8); Step d) Curing the casting compound (8); Step e) Remove the negative geometry (9), wherein a contour (14) is formed in the cured casting compound (8) that maps the geometry of the sensor interface (3) and / or sensor interface functional elements (3a, 3b, 4).

2. The method according to claim 1, characterized in that, It also includes step f), inserting the first sensor interface functional element (4) of the sensor interface (3), preferably a structured sensor interface functional element (4), into the outline (14) of the cured casting compound (8).

3. The method according to any one of claims 1 or 2, characterized in that, It also includes step g), inserting at least one additional sensor interface functional element (3a, 3b), preferably a sensor interface display element (3a) or a sensor interface setting element (3b), into the outline (14) of the cured casting compound (8) and / or into the first sensor interface functional element (4) of the sensor interface.

4. The method according to any one of claims 1 to 3, characterized in that, Step e) Forming the profile (14) in the casting compound (8) includes forming at least one undercut (15).

5. The method according to any one of claims 1 to 4, preferably claim 4, characterized in that, Step f) inserting the first sensor interface functional element (4) into the contour (14), and / or step g) inserting at least one additional sensor interface functional element (3a, 3b) into the at least one first sensor interface functional element (4) includes connecting the first sensor interface functional element (4) and / or the at least one additional sensor interface functional element (3a, 3b) to the contour (14) respectively.

6. The method according to claim 5, characterized in that, Connecting the first sensor interface functional element (4) to the contour (14) and / or connecting the at least one additional sensor interface functional element (31) to the contour (14) includes: fastening at least one fastening element (16), in particular fastening at least one hook element (16) of the sensor interface and / or sensor interface functional element (3) into the undercut (15) of the first contour (14).

7. The method according to any one of claims 1 to 6, characterized in that, Step e) Removing the negative geometry (9) includes melting or decomposing the negative geometry (9).

8. The method according to any one of claims 2 to 7, characterized in that, The first sensor interface functional element (4) is a sealing element (4), wherein step f) inserting the first sensor interface functional element (4) into the contour (14) of the cured casting compound (8) includes the step of inserting the sealing element (4) into the contour (14).

9. A sensor (1), preferably, a sensor manufactured by the method according to any one of claims 1 to 8, characterized in that, Includes a sensor interface and / or sensor interface functional elements (3), which are held by a contour (14) formed by a cured casting compound (8).

10. The sensor (1) according to claim 9, characterized in that, The profile (14) includes at least one undercut (15) designed to receive a fastening element (16) of the sensor interface (3).

11. The sensor (1) according to claim 9 or 10, characterized in that, The sensor interface functional element (3) includes at least one fastening element (16), preferably a snap-fit ​​element, especially a hook, for connecting the sensor interface functional element (3) to the undercut (15) of the contour (14).

12. The sensor (1) according to any one of claims 9 to 11, characterized in that, The undercut (15) is designed to at least partially surround the opening of the sensor housing (2), the opening being used to receive the sensor interface (3) and / or the sensor interface functional elements (3a, 3b, 4).

13. The sensor (1) according to any one of claims 8-12, characterized in that, The sensor interface (3) includes at least one first sensor interface functional element (4) and at least one additional sensor interface functional element (3a, 3b), wherein, preferably, the first sensor interface functional element (4) is a sealing element (4), and more preferably, the first sensor interface functional element (4) is made of an elastomer.

14. The sensor (1) according to any one of claims 8 to 13, characterized in that, The first sensor interface functional element (4), particularly in the form of a sensor interface functional element seal (4), includes at least one fastening element (16) designed to connect the sensor interface functional element seal (4) to the undercut (15) of the profile (14), wherein, most preferably, the at least one additional sensor interface functional element (3a, 3b) is held by the first sensor interface functional element (4).

15. The sensor (1) according to any one of claims 8-14, characterized in that, The additional sensor interface functional elements (3a, 3b) are configured such that the additional sensor interface functional elements (3a, 3b) are held by the interface sealing element (4) and the interface sealing element (4), especially if there is a fastening element (16) of the interface sealing element (4), is pressed into or against the undercut (15).

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