Sensor device, electrical device with sensor device and vehicle with sensor device

Description

[0001] A sensor device, an electrical device with a sensor device, and a vehicle with a sensor device are specified. Known sensor devices are disclosed in published patent applications DE 10 2016 119 430 A1, DE 10 2013 021 798 A, and JP 2003 240642 A, and in patent US 10,436,648 B2.

[0002] According to the invention, a sensor device comprises a sensor element.

[0003] According to a further embodiment, an electrical device comprises the sensor device. Furthermore, the electrical device can comprise an electrical load. The sensor device is particularly preferably arranged and fastened to the electrical load. The electrical load can particularly preferably be an electric motor. The electrical device and particularly preferably the electrical load have a mounting element on which the sensor device is arranged and fastened. The electrical device can accordingly have an electrical load with a mounting element that is provided and configured for the sensor device to be fastened thereto.

[0004] According to a further embodiment, a vehicle has the sensor device. The vehicle can be a road vehicle, a rail-bound vehicle, a watercraft, or an aircraft. The vehicle is particularly preferably a motor vehicle. The vehicle can, in particular, have an electrical consumer. The sensor device can be arranged and fastened to the electrical consumer. Accordingly, the vehicle can particularly preferably have the electrical device. Furthermore, it can also be possible for the electrical device to be part of a device such as a household device, a medical device, or an industrial device, wherein the device has the electrical consumer and the sensor device, and the sensor device is arranged and fastened to the electrical consumer.

[0005] The features and embodiments described above and below apply equally to the sensor device, the electrical device, the vehicle and the device.

[0006] The sensor element is particularly preferably a temperature sensor element, so that the sensor device can be provided and configured for temperature measurement. For this purpose, the sensor element can comprise a thermistor material. The thermistor material can be, for example, a thermistor or NTC thermistor material (NTC: "negative temperature coefficient") or a thermistor or PTC material (PTC: "positive temperature coefficient"). The sensor element can comprise or be, for example, a ceramic thermistor thermistor element. Such sensor elements can be preferred for measuring temperatures for monitoring and control in a wide variety of applications. The sensor element can, for example, be formed essentially from a thermistor material, for example in the shape of a chip, with applied electrical connections in the form of electrode layers.Furthermore, other sensor types as well as other sensor materials and designs are also possible.

[0007] According to the invention, the sensor device comprises a housing. The sensor element is arranged in and surrounded by the housing. Electrical leads that contact the sensor element are preferably led out of the housing.

[0008] Furthermore, the sensor device can be configured and provided to be arranged in proximity to, in indirect contact with, or preferably in direct contact with, the electrical load. Thus, the electrical device can particularly preferably have the sensor device arranged and attached directly to the electrical load.

[0009] Particularly preferably, the materials of the sensor device—for example, the material of the housing, the sensor element, wire contacts, electrical leads, and / or a potting material—exhibit high temperature stability. Particularly preferably, all materials of the sensor device exhibit high temperature stability. For example, the materials of the sensor device can be configured and provided for use at temperatures in a range of greater than or equal to -40°C and less than or equal to 200°C, so that the sensor device can be used within the specified temperature range.

[0010] Particularly preferably, the sensor device has a high dielectric strength. This can be particularly advantageous if the sensor device is arranged in the vicinity of, in indirect contact with, or in direct contact with a current-carrying and / or voltage-carrying surface of the electrical load. Particularly preferably, the sensor device is configured and intended to be operated in the vicinity of, in indirect contact with, or preferably in direct contact with, a surface that can have an electrical voltage of up to 2500 V.

[0011] Particularly preferably, the sensor device has a short response time. The response time of the sensor device can be characterized, for example, by the response time parameter t63, which is less than or equal to 10 s and particularly preferably less than or equal to 5 s. In the case of a sensor device for temperature measurement, t63 < 5 s can apply, in particular, for a temperature jump between 25°C and 85°C, wherein the measurement of the parameter can be performed in a liquid.

[0012] The housing is made up of several parts and has a cavity in which the sensor element is arranged. The housing further comprises a base part and a cover part, which can be connected to one another by a mechanical connection and / or an adhesive connection. The cavity can furthermore at least partially contain a gas, for example air, and / or a potting material, for example a plastic. The potting material, which can, for example, create a connection between the parts of the housing, is, for example, a resin, particularly preferably an epoxy. Alternatively or additionally, other potting materials are also possible. The housing comprises a plastic or is made thereof.

[0013] Particularly preferably, the housing, i.e., particularly preferably the plastic, has high temperature stability and high dielectric strength as described above. Furthermore, it is advantageous if the housing, i.e., particularly preferably the plastic, has high thermal conductivity in the case of a temperature sensor element in order to enable the short response time described above. Furthermore, the housing, i.e., particularly preferably the plastic, can have high mechanical strength in order to provide sufficient stability against mechanical stress during operation.

[0014] According to the invention, the housing comprises a plastic based on a liquid crystal polymer, LCP for short ("liquid crystal polymer").

[0015] Particularly preferred is an LCP whose starting polymer can be processed by a molding process, such as injection molding or extrusion. The plastic also contains a filler material.

[0016] In other words, the plastic, i.e., the LCP, contains a filler material, for example, in the form of dispersed particles and / or fibers and / or a bonded material. The filler material is boron nitride. The housing comprises or is made of a plastic formed by a thermoplastic cross-linked with boron nitride, and particularly preferably a highly cross-linked thermoplastic, namely an LCP. Such a material can be particularly suitable for ensuring high thermal conductivity combined with high dielectric strength.

[0017] According to a further embodiment, the mounting element is part of a busbar of the electrical load or is attached to a busbar of the electrical load. Accordingly, the mounting element can have at least one electrical voltage, at least during operation of the electrical load itself, and / or an electrical current can flow through the mounting element. The mounting element can be designed, for example, in the form of a tongue, in particular a metal tongue, onto which the sensor device can be pushed. The mounting element can thus be led out from a current-carrying rail, for example a copper rail.

[0018] According to the invention, the sensor device comprises a mechanical fastening element. The mechanical fastening element comprises a spring element.

[0019] Particularly preferably, the mechanical fastening element comprises or is made of a metallic spring element. The mechanical fastening element can be used to fix the sensor device to a mounting element, in particular an electrical load. Particularly preferably, the mounting element can be clamped between a part of the housing and a part of the fastening element when the sensor device is mounted.

[0020] In particular, the mechanical fastening element can be a metallic spring element designed as a metal clip, for example with or made of stainless steel, such as CrNi steel. The mechanical fastening element can be arranged and fastened to the housing or a part of the housing. For example, a part of the mechanical fastening element can be formed from a part of the housing and / or the mechanical fastening element can encompass a part of the housing, so that the mechanical fastening element is permanently and stably connected to the housing. A resilient restoring force of the mechanical fastening element can ensure constant contact with the mounting element to which the sensor device in the electrical device is attached, so that in the case of a temperature measurement, the surface temperature of the mounting element can be precisely recorded.

[0021] Furthermore, the mechanical fastening element can have a locking element. When the sensor device is mounted on the mounting element, the locking element can engage with a locking counter-element of the mounting element, thus ensuring secure fixation of the sensor device to the mounting element even under mechanical stress. The locking element can be designed, for example, as a locking lug and, when the sensor device is mounted on a mounting element, can engage with a locking counter-element designed as a window. Alternatively, the locking counter-element can be designed as a lug and the locking element as a window.

[0022] Furthermore, the housing or at least a part thereof can have at least one assembly-guiding element. The at least one assembly-guiding element can be selected from one or more insertion bevels, one or more guide grooves, or one or more chamfers. Here and below, a chamfer can preferably be a bevel or a square or round indentation or protrusion on a corner or side of the assembly-guiding element. The housing preferably has several assembly-guiding elements as at least one assembly-guiding element. Insertion bevels and guide grooves can facilitate sliding the sensor device onto the mounting element. Particularly preferably, the at least one assembly-guiding element is formed on the same part of the housing on which the mechanical fastening element is arranged.The mounting element can, for example, have a one-sided chamfer that is designed as a counterpart to a one-sided chamfer on the housing. This makes it easy to prevent inadvertent incorrect mounting of the sensor device on the mounting element according to the principle known as "Poka-Yoke." The at least one assembly-guiding element can thus provide guidance during assembly and / or prevent rotation during assembly.

[0023] The sensor device described here can particularly preferably be provided and configured to enable the fastest and most accurate temperature measurement possible of a current-carrying busbar, for example, a copper coil, in an electric motor of a vehicle. Compared to the sensor device described here, previous measurement systems are more complicated to integrate, for example, by gluing or overmolding. The system described here, with the sensor device and the mounting element, in contrast, meets requirements for simple and quick assembly and / or disassembly. One or more of the following features can be particularly advantageous: a lead-out of the busbar in the form of the mounting element in order to create space for the integration of the sensor device; the introduction of a locking counter-element, in particular a locking window, into the busbar and in particular into the mounting element for the permanent fixation of the sensor device; the introduction of a locking element, for example in the form of a locking lug in the form of a metallic barb, into the mechanical fastening element of the sensor device for the permanent fixation of the sensor device in the locking counter-element; the use of a mechanical fastening element, particularly preferably in the form of a metallic spring element, for the introduction of a permanent contact pressure between the mounting element and the sensor device; the introduction of a double guide groove as an assembly-guiding element in a housing part of the sensor device;The introduction of a one-sided chamfer (structural) into the mounting element and into a housing part of the sensor device to ensure anti-twist protection; the use of a thermoplastic highly cross-linked with boron nitride, namely an LCP, as the housing material to ensure high thermal conductivity and high dielectric strength.

[0024] With the sensor device described here, a temperature measurement of a metal surface of a busbar of an electric motor can be achieved in a particularly advantageous manner. This can be achieved with a miniaturized design for a highly integrated system. Furthermore, an easy and secure, screwless installation can be achieved.

[0025] Further advantages, advantageous embodiments and further developments emerge from the exemplary embodiments described below in conjunction with the figures.

[0026] They show: Figures 1A to 1H schematic representations of a sensor device according to an embodiment, Figures 2A and 2B schematic representations of an electrical device and a vehicle with a sensor device according to further embodiments, Figures 3A and 3B schematic representations of a mounting element for a sensor device according to a further embodiment and Figures 4A and 4B schematic representations of a mounting element and a sensor device according to a further embodiment.

[0027] In the exemplary embodiments and figures, identical, similar, or similarly functioning elements may be provided with the same reference numerals. The illustrated elements and their relative sizes are not to be considered to scale; rather, individual elements, such as layers, components, structural elements, and regions, may be exaggerated for clarity and / or clarity.

[0028] In the Figures 1A to 1H schematic representations of a sensor device 100 or at least parts thereof are shown. Figure 1A shows a three-dimensional view of Figure 1B shows a partially cutaway three-dimensional view of Figures 1C to 1E show three-dimensional views of some components of the sensor device 100 and the Figures 1F to 1H further views of the sensor device 100, wherein in Figure 1Ga partial top view and a partial sectional view. The following description applies equally to all Figures 1A to 1H .

[0029] The sensor device 100 has a sensor element 1. The sensor element 1 can be designed, for example, as a sensor chip. In particular, the sensor element 1 is designed purely by way of example as a temperature sensor element comprising a thermistor material, for example an NTC or PTC material, in chip form, which is provided with electrical connections in the form of metallizations forming electrode layers. Even if the following description refers to a temperature sensor, the sensor element 1 can alternatively also have a different functionality and a different structure, so that the sensor device can also be designed as a different type of sensor. In the exemplary embodiment shown, the sensor element 1 can in particular be an NTC thermistor element.

[0030] The electrical connections of the sensor element 1 can be electrically contacted via wire connections 2, for example in the form of soldered, electrically conductively glued, or bonded wires. The wire connections 2 are, for example, copper-clad FeNi wires. To protect the sensor element 1 and the wire connections 2, they are encapsulated, as shown. The encapsulation can, for example, comprise or be made of glass and / or a plastic. In the illustrated embodiment, due to temperature stability requirements, it can, in particular, be encapsulated with glass.

[0031] The sensor device 100 further comprises a housing 3. The sensor element 1 is arranged in the housing 3 and surrounded by the housing 3. Electrical supply lines 4 are connected to the wire connections 2, for example by a soldered connection, a welded connection, or a crimp connection, and are led out of the housing 3. The electrical supply lines 4 can be routed in a cable sheath 5, which in the illustrated embodiment comprises or is made of a fiberglass material, for example, to an electrical connector with corresponding electrical connection elements, via which the sensor device 100 can be connected.

[0032] The housing 3 is made up of several parts and has a cavity 30 in which the sensor element 1 is arranged. The housing 3, as shown, has a base part 31 and a cover part 32, which are connected to each other by a mechanical connection and / or an adhesive connection.

[0033] The cavity 30 can be at least partially filled with a gas, for example air, and / or a potting material 33, for example a plastic. The potting material 33 is, for example, a resin, particularly preferably an epoxy resin. The sensor element 1 and / or at least the wire connections 2 or parts thereof can be embedded in the potting material 33. For this purpose, for example, the base part 31 can have a recess that can form at least part of the cavity 30, as shown in Figure 1E shown, or have a support surface. The sensor element 1 can be inserted into or placed on the support surface, and the potting material 33 can then be applied. The potting material 33 can, for example, also create a connection between the parts of the housing 3, i.e., in the illustrated embodiment, between the base part 31 and the cover part 32.

[0034] The housing 3, i.e. the base part 31 and the cover part 32, comprises or is made of a plastic.

[0035] Particularly preferably, the housing 3, i.e., particularly preferably the plastic, has high temperature stability and high dielectric strength. Furthermore, it is advantageous if the housing 3, i.e., particularly preferably the plastic, has high thermal conductivity. Furthermore, the housing 3, i.e., particularly preferably the plastic, can have high mechanical strength in order to provide sufficient stability against mechanical stress during operation.

[0036] The housing comprises a plastic based on an LCP. Particularly preferred is an LCP whose starting polymer can be processed by a molding process, for example, by injection molding or extrusion. The plastic further comprises a filler material, which according to the invention is boron nitride.

[0037] Accordingly, the base part 31 and the cover part 32 comprise or are made of a plastic which is formed by a thermoplastic strongly cross-linked with boron nitride, namely an LCP.

[0038] Due to the materials used, the sensor device 100 is designed and intended to be arranged in the vicinity of, in indirect contact with, or preferably in direct contact with, an electrical consumer.

[0039] Particularly preferably, all materials of the sensor device 100—that is, the material of the housing 3, the sensor element 1, the encapsulation of the sensor element 1, the wire connections 2, the electrical leads 4, and the potting material 33—have high temperature stability. As described in the general section, the materials of the sensor device 100 are selected such that the sensor device 100 can be used in an electrical device during operation at operating temperatures that can preferably be within a temperature range of greater than or equal to -40°C and less than or equal to 200°C. Furthermore, the sensor device 100 has high dielectric strength. Particularly preferably, the sensor device 100 is configured and intended to be operated in the vicinity of, in indirect contact with, or preferably in direct contact with, a surface that can have an electrical voltage of up to 2500 V.Furthermore, the sensor device 100 has a short response time, in particular with t63 < 5 s for a temperature jump between 25°C and 85°C.

[0040] Furthermore, the sensor device 100 has a mechanical fastening element 7. The mechanical fastening element is designed as a metallic spring element. By means of the mechanical fastening element 7, the sensor device 100 can be fixed to a mounting element, in particular to a mounting element of an electrical load, as explained further below.

[0041] In particular, the mechanical fastening element 7 can be designed as a metal clamp, for example with or made of stainless steel, such as CrNi steel. The mechanical fastening element 7 is fastened to the housing 3 and, in the exemplary embodiment shown, in particular to the base part 31. For example, a part of the mechanical fastening element 7 can be formed from a part of the housing 3 and / or the mechanical fastening element 7 can encompass a part of the housing 3, so that the mechanical fastening element is permanently and stably connected to the housing 3. As shown, for example, in the Figures 1A , 1C and 1EAs can be seen, a part of the mechanical fastening element 7 encompasses a part of the base part 31. The base part 31 has corresponding support surfaces 34 on the side opposite a bottom side 35. If the sensor device 100 is pushed onto a mounting element as described further below, the mechanical fastening element 7 generates a clamping force by which the sensor device 100 can be securely held. In particular, the mounting element, as described for example further below in Figure 4A shown, clamped between the underside 35 of the housing 3 and the mechanical fastening element 7.

[0042] Furthermore, the mechanical fastening element 7 has a locking element 70. The locking element 70 can be designed as a locking lug, as shown, and, when the sensor device is mounted on the mounting element, can engage with a corresponding locking counter-element of the mounting element in the form of a window, so that a secure fixation of the sensor device to the mounting element can be ensured even under mechanical loads.

[0043] Furthermore, the housing 3, in the embodiment shown in particular the base part 31, has at least one assembly-guiding element 36. As shown in particular in Figure 1DAs can be seen, the base part 31 has a double guide groove 38 with insertion bevels 39 and a one-sided chamfer 37 as assembly-guiding elements 36. As will be described further below, the mounting element on which the sensor device 100 is mounted also has a one-sided chamfer, which is designed as a counterpart to the one-sided chamfer 37 on the housing 3.

[0044] In Figure 2A An electrical device 200 is shown, which has a sensor device 100 as described in the previous embodiment. Furthermore, the electrical device 200 has an electrical load 20, to which the sensor device 100 is directly arranged and fastened. The electrical load 20 can particularly preferably be an electric motor. The electrical device 200 and in particular the electrical load 20 has a mounting element 8, which in conjunction with the Figures 3A and 3Bdescribed in more detail, on which the sensor device 100 is arranged and fastened. Due to the previously described resilient restoring force of the mechanical fastening element of the sensor device 100, constant contact with the mounting element 8 can be ensured, so that the surface temperature of the mounting element 8 can be accurately detected.

[0045] In the illustrated embodiment, the mounting element 8 is part of a busbar 21, for example a copper bar, of the electrical load 20. Alternatively, the mounting element 8 can also be attached to a busbar 21 of the electrical load 20. Accordingly, the mounting element 8 can have at least one electrical voltage, at least during operation of the electrical load 20 itself, and / or an electrical current can flow through the mounting element 8.

[0046] In Figure 2BA vehicle 1000 is shown that has the electrical device 200. Thus, the vehicle 1000 has the sensor device 100 and the electrical load 20, in particular an electric motor. The vehicle 1000 can be a road vehicle, a rail vehicle, a watercraft, or an aircraft. As indicated, the vehicle 1000 is particularly preferably a motor vehicle.

[0047] In the Figures 3A and 3B An exemplary embodiment of the mounting element 8 is shown in a top view and a side view. The mounting element 8 can, as shown, be designed, for example, in the form of a tongue, in particular a metal tongue, onto which the sensor device 100 can be pushed. For this purpose, the mounting element 8 has a push-on area 80, which slides into the area formed by the assembly-guiding elements 36 in the underside 35 of the housing 3 of the Figures 1A to 1HThe mounting element 8 fits the sensor device 100 shown. With a connection area 83, the mounting element 8 can be attached to the electrical load, for example, to a busbar, as described above. Alternatively, the connection area 83 can also be part of the busbar. The arrangement of the push-on area 80, for example, bent or folded at an angle of approximately 45°, relative to the connection area 83 can facilitate mounting of the sensor device 100 on the electrical load.

[0048] As a counterpart to the locking element 70 of the mechanical fastening element 7 of the sensor device 100, the mounting element 8 has a locking counter element 81, which in the embodiment shown is designed as a window into which the locking element of the sensor device, designed as a locking lug, can engage.

[0049] Furthermore, the mounting element 8 has a one-sided chamfer 82, which is formed as a counterpart to the chamfer 37 in the underside 35 of the housing 3 of the sensor device 100.

[0050] In Figure 4A The sensor device 100 is arranged on the mounting element 8 and is shown as fully pushed on. The locking element of the sensor device 100 and the locking counter-element of the mounting element 8, as well as the clamping force of the mechanical fastening element of the sensor device, enable a secure and mechanically resilient fixation of the sensor device 100 on the mounting element 8.

[0051] As in Figure 4BAs indicated, unintentional incorrect mounting of the sensor device 100 on the mounting element 8 can be easily prevented by the assembly-guiding elements, in particular the one-sided bevel in the underside of the sensor device and the corresponding one-sided bevel in the mounting element 8. Thus, the assembly-guiding elements of the sensor device 100 can provide guidance during assembly and prevent twisting during assembly. Furthermore, the angled design of the mounting element 8 can also enable easy identification of the correct mounting direction. List of reference symbols

[0052] 1Sensor element 2Wire connection 3Housing 4Electrical supply line 5Cable sheath 7Mechanical fastening element 8Mounting element 20Electrical consumer 21Busbar 30Cavity 31Base part 32Cover part 33Potting material 34Supporting surface 35Underside 36Assembly-conductive element 37Bevel 38Guide groove 39Insertion bevel 70Locking element 80Sliding area 81Locking counter element 82Bevel 83Connection area 100Sensor device 200Electrical device 1000Vehicle

Claims

1. Sensor device (100) comprising a sensor element (1) in a housing (3), wherein a mechanical fastening element (7) comprising a spring element is arranged at and fastened to the housing, characterized in that the housing comprises a plastic based on a filled liquid crystal polymer, wherein the plastic comprises a liquid crystal polymer filled with boron nitride, wherein the housing comprises a base part (31) and a cover part (32) connected to one another, and a cavity (30) with the sensor element arranged therein.

2. Sensor device according to Claim 1, wherein the sensor element is a temperature sensor element.

3. Sensor device according to either of the preceding claims, wherein the mechanical fastening element comprises a latching element (70).

4. Sensor device according to any of the preceding claims, wherein the housing comprises at least one mounting-guiding element (36) selected from one or more insertion bevels (39), one or more guide grooves (38), one or more chamfers (37).

5. Sensor device according to any of the preceding claims, wherein the cavity at least partly comprises a potting material (33).

6. Sensor device according to any of the preceding claims, wherein all materials of the sensor device have a temperature stability for use at temperatures at least in a range of greater than or equal to -40°C and less than or equal to 200°C.

7. Sensor device according to any of the preceding claims, wherein the sensor device is provided and configured for operation in direct contact with a surface having a voltage of up to 2500 V.

8. Electrical apparatus (200) comprising a sensor device (100) according to any of Claims 1 to 7 and an electrical consumer (20), wherein the sensor device is arranged at the electrical consumer and is fastened thereto by the mechanical fastening element (7) by a clamping force.

9. Electrical apparatus according to Claim 8, wherein the electrical consumer is an electric motor.

10. Electrical apparatus according to Claim 8 or 9, wherein the electrical consumer comprises a mounting element (8), the sensor device being arranged at and fastened to said mounting element.

11. Electrical apparatus according to the preceding claim, wherein the mounting element is part of a busbar (21) of the electrical consumer.

12. Electrical apparatus according to Claim 10 or 11, wherein the mounting element is embodied in the form of a metal tongue, onto which the sensor device is pushed.

13. Electrical apparatus according to any of Claims 10 to 12, wherein the mounting element comprises a mating latching element (81), into which a latching element (70) of the mechanical fastening element is latched.

14. Electrical apparatus according to any of Claims 10 to 13, wherein the mounting element comprises a one-sided chamfer (82) embodied as a counterpart to a one-sided chamfer (37) at the housing.

15. Vehicle (1000) comprising an electrical apparatus (200) according to any of Claims 8 to 14.