Method for manufacturing a sensor module and sensor module

Abstract

The present invention relates to a method for manufacturing a sensor module (1) comprising at least a sensor head (6), a metal cover (3), a connector module (4), and a connector element (2), the method comprising the following: - a step (S1) of providing the connector element (2) and the metal cover (3); - a step (S2) of attaching the connector element (2) to the metal cover (3), wherein the connector element (2) has a fusible material (5) on a surface (2a) facing the metal cover (3) in at least a partial region, and the metal cover (3) has a region (F) in at least a partial region where the fusible material (5) of the connector element (2) is applied on a surface (3a) facing the connector element (2); - a step of heating the metal cover (3) on a surface (3b) opposite to the connector element (2), as a result of which the fusible material (5) melts; - a step (S4) of establishing a connection between the connector element (2) and the metal cover (3) by means of the fusible material (5) in at least the region (F) provided on the metal cover (3); - a step (S5) of fixing the sensor head (6) to the metal cover (3); and relates to a method having these steps.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a sensor module and a sensor module manufactured by this method.

Background Art

[0002] With the evolution from semi-autonomous vehicles to fully autonomous vehicles, the number of sensor modules required for such vehicles has been steadily increasing. In addition, the specifications and tasks of the modules are also changing more and more. Many sensors are mounted externally and must therefore have waterproofing and resistance to dirt / dust and chemical substances. Also, the performance required for sensors for autonomous driving is increasing.

[0003] From the prior art, it is known, for example, to seal the gap between a component and a metal plate with an adhesive or a potting material. It is also known to seal the gap with an O-ring or a similar seal and attach the connector to the metal plate by screwing or a similar fixing process. Other known variants would be to overmold the connector onto the metal plate by an injection molding process.

[0004] The problem with these methods is that, for example, the potting process is a very complex process and there are many influencing factors, such as contaminants in the material, etc., in order to always obtain good results. Furthermore, sealing with an O-ring or a similar seal can enhance the surging mechanism of the sensor. Moisture in the sensor can cause a decrease in performance.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, an object of the present invention is to provide a method capable of manufacturing a sensor module excellent in robustness and waterproofness at low cost.

Means for Solving the Problems

[0006] This object is achieved by the subject matter of claims 1 and 4.

[0007] Another advantageous design and embodiment is the gist of the dependent claims.

[0008] The first consideration was that incorporating and sealing a plastic connector into the sensor represents a basic method step. Therefore, these steps in particular should be improved and optimized in terms of cost.

[0009] Thus, according to the present invention, a manufacturing method for a sensor module comprising at least a sensor head, a metal cover, a connector module, and a connector element is proposed by the following steps: - providing a connector element and a metal cover; - attaching the connector element to the metal cover, wherein the connector element has a fusible material on a surface facing the metal cover in at least a partial region, and the metal cover has a region on a surface facing the connector element where the fusible material of the connector element is applied in at least a partial region; - heating the metal cover on a surface opposite to the connector element, as a result of which the fusible material melts; - establishing a connection by means of the fusible material in at least a region provided on the metal cover between the connector element and the metal cover; - fixing the sensor head to the metal cover.

[0010] The connector element is designed, for example, as a plastic housing for the connector module. The connector element is designed such that the connector module can be inserted into the connector element.

[0011] In the proposed method, the connector element is pushed into the metal cover, the fusible material is directly above the area of the metal cover, and the material and the area of the metal cover have substantially the same geometry. On the other hand, the metal cover is heated on the side opposite to the connector element so that the fusible material is melted. After melting, the fusible material flows into the area intended for that purpose, thus establishing a connection between the metal cover and the connector element.

[0012] This connector module can have all the common connector interfaces related to the automotive field.

[0013] In a preferred design, a structure is provided into which the melted fusible material flows in order to establish a connection on the area of the metal cover. This structure is particularly advantageous because such a structure has, for example, grooves or generally recesses into which a liquid material can flow. As an advantage, a more robust connection is established between the connector element and the metal cover.

[0014] Preferably, the heating of the metal cover is performed by a laser, by a heating plate, or inductively. These methods are possible preferred methods to ensure that the metal cover is heated particularly evenly and quickly.

[0015] Furthermore, according to the present invention, a sensor module comprising at least a sensor head, a metal cover, a connector module, and a connector element is proposed. The connector element has a fusible material on the surface facing the metal cover at least in a partial area. The metal cover has an area where a fusible material is applied on the surface facing the connector element at least in a partial area. Each of the connector element and the metal plate has a central recess into which the connector module can be inserted. By heating the metal cover, the connection between the connector element and the metal plate is established as a result of the melting of the fusible material on the area of the metal cover.

[0016] The connector element is designed, for example, as a plastic housing for a connector module. The connector element is designed such that the connector module can be inserted into the connector element.

[0017] In the proposed method, the connector element is pushed into the metal cover, the fusible material is located directly above the area of the metal cover, and the material and the area of the metal cover have substantially the same geometry. On the other hand, the metal cover is heated on the side opposite to the connector element so that the fusible material is melted. After melting, the fusible metal flows into the area intended therefor, thus establishing a connection between the metal cover and the connector element.

[0018] The metal cover consists of, for example, the aluminum alloy AL99.5. However, other materials are also conceivable.

[0019] The connector module can have all common connector interfaces related to the automotive field.

[0020] In a particularly preferred embodiment, the area of the metal cover is designed such that the fusible material flows into this structure and a connection is established between the metal cover and the connector element. This structure is particularly advantageous because such a structure has, for example, grooves or recesses into which the liquid material can flow. As an advantage, a more robust connection is established between the connector element and the metal cover.

[0021] Particularly preferably, the structure of the area of the metal cover is produced using a laser or by punching or turning. These methods are preferred material processing methods that can particularly easily realize the construction of the metal cover within a predetermined area. Other metal processing methods for producing the structure are also conceivable.

[0022] In another preferred design, the area is arranged around the recess for the connector module in the form of a ring. This is advantageous because in this way the size of the sealing area required can be minimized, which in turn affects the required amount of the fusible material.

[0023] Furthermore, the fusible material is particularly preferably arranged around the recess for the connector module in the form of a ring on the connector element. The arrangement in the form of a ring is advantageous because in this way the fusible material can be advantageously reduced and at the same time a sufficient seal can be ensured.

[0024] Other geometries of the area and the fusible material are also conceivable, but if the geometry changes, it must be ensured that the two geometries substantially match.

[0025] Preferably, when connecting the metal plate to the connector element, the connector module is arranged on the metal plate or within the connector element. Correspondingly, the connector module may be integrated into the connector element or arranged in the recess of the metal plate before the connection step. There is no difference in establishing the connection, and therefore these variations as alternatives are possible without further adjustment.

[0026] Preferably, the fusible material is plastic. Basically, any plastic with a melting point lower than that of the connector element itself can be used here.

[0027] Other advantageous designs are the gist of the drawings. #

Brief Description of the Drawings

[0028]

Figure 1

Figure 2a

Figure 2b

Figure 3a

Figure 3b

Figure 4

Figure 5

DETAILED DESCRIPTION OF THE INVENTION

[0029] Figure 1 shows a schematic flow diagram of a method according to one embodiment of the present invention. In step S1, a connector element 2 and a metal cover 3 are provided. In step S2, the connector element 2 is attached to the metal cover 3. The connector element 2 has a fusible material 5 on the surface 2a facing the metal cover 3 at least in a partial region. The metal cover 3 has a region F on the surface 3a facing the connector element 2 at least in a partial region, where the fusible material 5 of the connector element 2 is applied. In step S3, the metal cover 3 is heated on the surface 3b opposite to the connector element, and the fusible material 5 is melted by the heating. In step S4, a connection between the connector element 2 and the metal cover 3 is established, and the metal cover is provided by the fusible material 5 at least in the region F. In step S5, the sensor head 6 is fixed to the metal cover 3.

[0030] Figures 2a and 2b each show a schematic representation of a connector element according to one embodiment of the present invention. The connector element 2 in Figure 2a has a fusible material 5 on the surface 2a facing the metal cover. Further, in the design according to Figure 2a, the connector module 4 is already incorporated into the connector element 2. The representation in Figure 2b substantially corresponds to Figure 2a, but in Figure 2b, the connector module 4 is not arranged within the connector element 2, and there is only a recess A2 in Figure 2b.

[0031] Each of FIGS. 3a and 3b shows a schematic representation of a metal cover according to one embodiment of the present invention. In the representation of FIG. 3a, the metal cover 3 has a region F on the surface 3a facing the connector element, where the fusible material 5 of the connector element 2 is applied. This region F may have a structure for enhancing the durability of the connection. A recess A3 into which the connector module 4 can be inserted is shown at the center of the metal cover 3. The representation of FIG. 3b substantially corresponds to that of FIG. 3a, but in FIG. 3b, the sensor module 4 is arranged within the recess A3 of the metal cover 3.

[0032] FIG. 4 shows a schematic representation of a connector element combined with a metal cover according to one embodiment of the present invention. In this case, the connector element 2 is attached to the metal cover 3 by pressure P. In this representation, the fusible material 5 is visible between the connector element 2 and the metal cover 3. The metal cover 3 is heated at a high temperature T on the surface 3b opposite to the connector element 2, so that the fusible material 5 is melted.

[0033] FIG. 5 shows a schematic representation of a sensor module according to one embodiment of the present invention. Here, the sensor module 1 includes a connector element 2 having a fusible material 5 and a metal cover 3, and the metal cover 3 has a region F where the fusible material 5 is applied. Further, in this embodiment, the connector module 4 is arranged within the metal cover 3. As already shown, the connector module 4 may also be arranged within the connector element 2, and then the connector element 2 may be connected to the metal cover 3. Further, a sensor head 6 is provided for the sensor module 1 and is connected to the metal cover 3.

Explanation of Reference Numerals

[0034] 1 Sensor module 2 Connector element 2a Surface facing the metal cover 3 Metal cover 3a Surface facing the connector element 3b Surface opposite to the connector element 4 Connector module 5 Fusible material 6 Sensor head Recess of A2 connector element Recess of A3 metal cover F area P Pressure S1~S5 Method steps T Temperature

Claims

1. A method for manufacturing a sensor module (1) comprising at least a sensor head (6), a metal cover (3), a connector module (4), and a connector element (2), the method comprising the following steps: - A step (S1) of providing the connector element (2) and the metal cover (3); - A step (S2) of attaching the connector element (2) to the metal cover (3), wherein the connector element (2) has a fusible material (5) on a surface (2a) facing the metal cover (3) in at least a partial region, and the metal cover (3) has a region (F) on a surface (3a) facing the connector element (2) in at least a partial region, where the fusible material (5) of the connector element (2) is applied; - A step of heating the metal cover (3) on a surface (3b) opposite to the connector element (2), as a result of which the fusible material (5) melts; - A step (S4) of establishing a connection between the connector element (2) and the metal cover (3) by means of the fusible material (5) at least in the region (F) provided on the metal cover (3); - A step (S5) of fixing the sensor head (6) to the metal cover (3). A method comprising the above steps.

2. The method according to claim 1, characterized in that a structure is provided into which the melted fusible material (5) flows in order to establish the connection on the region (F) of the metal cover (3).

3. The method according to claim 1, characterized in that the heating of the metal cover (3) is performed by a laser, a heating plate, or inductively.

4. A sensor module (1) including at least a sensor head (6), a metal cover (3), a connector module (4), and a connector element (2), wherein the connector element (2) has a fusible material (5) on a surface (2a) facing the metal cover (3) in at least a partial region, the metal cover (3) has a region (F) in at least a partial region where the fusible material (5) is applied on a surface (3a) facing the connector element (2), the connector element (2) and the metal plate (3) each have a central recess (A2, A3) into which the connector module (4) can be inserted, and by heating the metal cover (3), a connection between the connector element (2) and the metal plate (3) is established as a result of melting of the fusible material (5) on the region of the metal cover (3).

5. The sensor module (1) according to claim 4, characterized in that the region (F) of the metal cover (3) has a structure, and the fusible material (5) is designed to flow into this structure to establish a connection between the metal cover (3) and the connector element (2).

6. The sensor module (1) according to claim 5, characterized in that the structure of the region (F) of the metal cover (3) is produced by punching or turning using a laser.

7. The sensor module (1) according to claim 5 or 6, characterized in that the region (F) is arranged in the form of a ring around the recess (A3) for the connector module (4).

8. The sensor module (1) according to claim 4, characterized in that the fusible material (5) is arranged in the form of a ring around the recess (A2) for the connector module (4) on the connector element (2).

9. The sensor module (1) according to any one of claims 4 to 8, characterized in that when connecting the metal cover (3) to the connector element (2), the connector module (4) is arranged on the metal cover (3) or in the connector element (2).

10. The sensor module (1) according to claim 4, characterized in that the fusible material (5) is plastic.

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