Sensor device, electrical device having the sensor device, and vehicle having the sensor device

Abstract

SOLUTION: A sensor device (100) has a sensor element (1) in a housing (3), where a mechanical fastening element (7) with a spring element is arranged and fastened to the housing. An electrical device (200) has the sensor device (100). A vehicle (1000) has the sensor device (100).EFFECT: The sensor device can achieve temperature measurement of a metal surface of a busbar of an electric motor, and achieve a miniaturized design for a highly integrated system, and an easy and secure screwless installation.SELECTED DRAWING: Figure 1A

Description

Technical Field

[0001] A sensor device, an electrical device having the sensor device, and a vehicle having the sensor device are presented.

Summary of the Invention

[0002] According to at least one embodiment, the sensor device has a sensor element.

[0003] According to a further embodiment, the electrical device has the sensor device. Further, the electrical device can have an electrical consumption part. The sensor device is particularly preferably arranged and fixed on the electrical consumption part. The electrical consumption part can particularly preferably be an electric motor. Particularly preferably, the electrical device, particularly preferably the electrical consumption part, has a mounting element, and the sensor device is arranged and fixed on the mounting element. The electrical device can correspondingly have an electrical consumption part having a mounting element, and the mounting element is designed and adapted such that the sensor device is fixed thereon.

[0004] According to a further embodiment, the vehicle has the sensor device. The vehicle can be a road vehicle, a rail vehicle, a ship or an aircraft. Particularly preferably, the vehicle is a motor vehicle. The vehicle can particularly have an electrical consumption part. The sensor device can be arranged and fixed on the electrical consumption part. Correspondingly, the vehicle can particularly preferably have an electrical device. Further, it is also possible that the electrical device is part of a device such as a household device, a medical device or an industrial device, in which case the device has an electrical consumption part and a sensor device, and the sensor device is arranged and fixed on the electrical consumption part.

[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, and as a result, the sensor device can be designed and adapted for temperature measurement. For this purpose, the sensor element can include a thermistor material. The thermistor material can be, for example, an NTC thermistor material (NTC: "negative temperature coefficient") or a PTC thermistor material (PTC: "positive temperature coefficient"). The sensor element can include, for example, or be a ceramic NTC thermistor element. Such a sensor element may be preferred for measuring temperature for monitoring and control in a wide range of applications. The sensor element can be formed, for example, substantially, for example, in chip form, of a thermistor material to which an electrical connection in the form of an electrode layer is attached. Furthermore, other sensor types as well as other sensor materials and configurations are possible.

[0007] According to a further embodiment, the sensor device has a housing. The sensor element is preferably arranged within and surrounded by the housing. The electrical conductor in contact with the sensor element is preferably led out from the housing.

[0008] Furthermore, the sensor device can be designed and adapted to be arranged in the vicinity of, in indirect contact with, or preferably in direct contact with, an electrical consumer. Thus, the electrical device can particularly preferably have the sensor device arranged and fixed directly on the electrical consumer.

[0009] Particularly preferably, the materials of the sensor device, i.e., for example, the housing, the sensor element, the wire contacts, the electrical conductors and / or the potting material, have high temperature stability. Particularly preferably, all the materials of the sensor device have high temperature stability. For example, the materials of the sensor device can be designed and adapted for use at temperatures in the range from -40 °C to 200 °C. As a result, the sensor device can be used in the temperature range described above.

[0010] Particularly preferably, the sensor device has a high breakdown voltage. This can be particularly advantageous when the sensor device is arranged in the vicinity of, in indirect contact with, or in direct contact with the surface of an electrically consuming component that is energized and / or has a voltage. Particularly preferably, the sensor device is adapted and designed to operate in the vicinity of, in indirect contact with, or preferably in direct contact with a surface that can have a voltage up to 2500V.

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

[0012] The housing can be single-piece or multi-piece and can in particular have a cavity in which the sensor element is arranged. For example, the housing can have a base part and a cover part that can be connected to each other by mechanical connection and / or adhesive bonding. The cavity can further contain at least partially a gas such as air and / or a potting material such as plastic. A potting material that can provide a connection between parts of the housing, for example, is resin, particularly preferably epoxy. Alternatively or additionally, other potting materials are also possible. The housing preferably contains or consists of plastic. Particularly preferably, the housing, i.e., particularly preferably plastic, has a high temperature stability and a high breakdown voltage as described above. Furthermore, in order to enable the short response time described above, it is advantageous if the housing, i.e., particularly preferably plastic, has a high thermal conductivity in the case of a temperature sensor element. Furthermore, the housing, i.e., particularly preferably plastic, can have a high mechanical strength in order to have sufficient stability against mechanical loads during operation.

[0013] The plastic can preferably be a thermoplastic. Particularly preferably, the housing comprises or consists of a plastic based on a liquid crystal polymer, abbreviated as LCP ("liquid crystal polymer"). Particularly preferably, an LCP is used whose starting polymer can be processed by a shaping process, i.e., for example, by injection molding or extrusion molding. The plastic can further comprise a filler. In other words, a filler in the form of, for example, dispersed particles and / or fibers and / or a bound material can be present in the plastic, i.e., particularly preferably in the LCP. The filler is, for example, boron nitride. Particularly preferably, the housing comprises or consists of a plastic formed by a thermoplastic, particularly preferably an LCP, crosslinked with boron nitride, particularly preferably strongly crosslinked. Such a material can be particularly suitable for ensuring a high breakdown voltage and at the same time a high thermal conductivity.

[0014] According to a further embodiment, the attachment element is part of or fixed to a bus bar of the electrical consumer. Correspondingly, the attachment element can have at least one voltage and / or current can flow through the attachment element, at least during operation of the electrical consumer itself. The attachment element can be formed, for example, in the form of a tongue, particularly a metal tongue, onto which the sensor device can be pushed. Thus, the attachment element can be derived from an energized rail, for example a copper rail.

[0015] According to a further embodiment, the sensor device has a mechanical fixing element. The mechanical fixing element can particularly have or be a spring element. Particularly preferably, the mechanical fixing element comprises or consists of a metal spring element. By means of the mechanical fixing element, the fixing of the sensor device to the attachment element of the electrical consumer can particularly be achieved. Particularly preferably, the attachment element can be clamped between a part of the housing and a part of the fixing element in the state in which the sensor device is attached.

[0016] In particular, the mechanical fixing element can be a metallic spring element formed as a metal clip comprising or consisting of stainless steel such as CrNi steel. The mechanical fixing element can be arranged and fixed to the housing or a part of the housing. For example, a part of the mechanical fixing element can be deformed from a part of the housing and / or the mechanical fixing element can wrap around a part of the housing, so that the mechanical fixing element is permanently and stably connected to the housing. Due to the elastic restoring force of the mechanical fixing element, a permanent contact between the sensor device in the electrical apparatus and the attached element can be ensured. As a result, in the case of temperature measurement, the surface temperature of the attached element can be accurately determined.

[0017] Furthermore, the mechanical fixing element can have a latching element. The latching element can engage with a latching counter-element of the attached element when the sensor device is attached to the attached element, so that a secure fixing of the sensor device to the attached element can be ensured even under mechanical loads. The latching element can be formed, for example, as a latching nose (Rastnase) and can engage in a latching counter-element formed as a window when the sensor device is attached to the attached element. Alternatively, the latching counter-element can be formed as a nose and the latching element can be formed as a window, respectively.

[0018] Furthermore, the housing or at least a part thereof can have at least one mounting guide element. The at least one mounting guide element can be selected from one or more insertion slopes, one or more guide grooves, and one or more chamfers. The chamfer, herein and hereinafter, can preferably be an inclined portion at a corner or a surface of the mounting guide element, or a angular or rounded depression or protrusion. Preferably, the housing has a plurality of mounting guide elements as the at least one mounting guide element. The introduction slope and the guide groove can result in easier pushing of the sensor device onto the mounting element. Particularly preferably, the at least one mounting guide element is formed in the same part of the housing where the mechanical fixing element is also arranged. The mounting element can have, for example, a one-sided chamfer, and the chamfer is formed as a counterpiece to the one-sided chamfer of the housing. Thereby, an unintentional incorrect mounting of the sensor device onto the mounting element can be avoided in a simple way by the principle known as "poka-yoke". Therefore, the at least one mounting guide element can achieve guiding during mounting and / or anti-rotation during mounting.

[0019] The sensor device described herein can be designed and adapted, particularly preferably, in an electric motor of a vehicle to enable as rapid and accurate as possible temperature measurement of a live busbar, such as a copper coil. Conventional measurement systems are complicated to integrate, for example, by adhesion or overmolding, compared to the sensor device described herein. In contrast, the system having the sensor device and the mounting element described herein meets the requirements of simple and rapid mounting and / or removal. In that case, in particular, one or more of the following features can be advantageous: - Deriving a busbar in the form of a mounting element to create space for integrating the sensor device; - Introducing a latch counter element, particularly a latch window, into the busbar, particularly the mounting element, to permanently fix the sensor device; - Introducing a latching element in the form of a latching nose, for example in the form of a metal hook (Widerhaken), into the mechanical fixing element of the sensor device in order to permanently fix the sensor device to the latching counter element; - Using a mechanical fixing element in the form of a spring element, particularly preferably made of metal, for introducing a permanent contact pressure between the mounting element and the sensor device; - Introducing a double guide groove as a mounting guide element into the housing part of the sensor device; - Inserting chamfered parts (structurally) on one side into the mounting element and the housing part of the sensor device respectively to ensure anti-rotation; - Using, as the housing material, a thermoplastic plastic strongly cross-linked with boron nitride, particularly LCP, in order to ensure a high edge voltage and at the same time a high thermal conductivity

[0020] Using the sensor device described herein, particularly preferably, temperature measurement of the metal surface of the bus bar of an electric motor can be realized. This can be achieved by a miniaturized design for a highly integrated system. Furthermore, easy and reliable screwless mounting can be realized.

[0021] Further advantages, advantageous embodiments and developments will become apparent from the examples described below in connection with the drawings.

Brief Description of the Drawings

[0022]

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 1E

Figure 1F

Figure 1G

Figure 1H

Figure 2A

Figure 2B

Figure 3A

Figure 3B

Figure 4A

Figure 4B

DETAILED DESCRIPTION OF THE INVENTION

[0023] In the embodiments and the drawings, the same, similar, or equivalently functioning elements may each be assigned the same reference numeral. The illustrated elements and the ratios of their sizes to each other are not to scale, rather, individual elements such as, for example, layers, components, members, and regions may be shown exaggeratedly large for better illustration possibilities and / or better understanding.

[0024] In FIGS. 1A to 1H, schematic diagrams of the sensor device 100 or at least a part thereof are shown. FIG. 1A shows a three-dimensional overhead view, FIG. 1B shows a partially cut-away three-dimensional view, FIGS. 1C to 1E show three-dimensional views of some components of the sensor device 100, FIGS. 1F to 1H show further views of the sensor device 100, and FIG. 1G shows a partial overhead view and a partial cross-sectional view. The following description applies equally to all of FIGS. 1A to 1H.

[0025] The sensor device 100 has a sensor element 1. The sensor element 1 can be formed, for example, as a sensor chip. In particular, as a pure example, the sensor element 1 is formed as a temperature sensor element having a chip-shaped thermistor material, for example, an NTC material or a PTC material, provided with an electrical connection portion in the form of a metallization forming an electrode layer. Even when the following description relates to a temperature sensor, the sensor element 1 can alternatively also have other functions and other structures, and as a result, the sensor device can also be formed as other sensor types. In the illustrated embodiment, the sensor element 1 can in particular be an NTC thermistor element.

[0026] The electrical connection portion of the sensor element 1 can be electrically contacted, for example, via a wire connection portion 2 in the form of a soldered wire, a conductively adhered wire, or a bonded wire. The wire connection portion 2 is, for example, a copper-coated FeNi wire. To protect the sensor element 1 and the wire connection portion 2, they are covered by a capsule as illustrated. The capsule can, for example, contain or consist of glass and / or plastic. In the illustrated embodiment, due to the requirements of temperature stability, it can in particular be a glass capsule.

[0027] Furthermore, the sensor device 100 has a housing 3. The sensor element 1 is arranged within the housing 3 and surrounded by the housing 3. The electrical conductor 4 is connected to the wire connection portion 2, for example, by a soldered joint, a welded joint, or a crimped joint, and led out from the housing 3. In the illustrated embodiment, the electrical conductor 4 can be led to an electrical plug connector having corresponding electrical connection elements within a cable sleeve 5 containing or consisting of, for example, a glass fiber material. The sensor device 100 can be connected via the electrical plug connector.

[0028] The housing 3 can be single-piece or multi-piece and in particular has a cavity 30 in which the sensor element 1 is arranged. For example, the housing 3 can have a base part 31 and a cover part 32 which are connected to one another by mechanical connection and / or adhesive bonding, as shown in the illustration.

[0029] The cavity 30 can be at least partially filled with a gas such as air and / or a potting material 33 such as plastic. The potting material 33 is, for example, a resin and particularly preferably an epoxy resin. The sensor element 1 and / or at least the wire connection part 2 or a part thereof can be embedded in the potting material 33. For this purpose, for example, the base part 31 can have a depression or a support surface which forms at least part of the cavity 30, as shown in FIG. 1E. The sensor element 1 can be inserted into the depression or placed on the support surface. Subsequently, the potting material 33 can be applied. The potting material 33 can also provide a connection between parts of the housing 3, i.e. between the base part 31 and the cover part 32 in the illustrated embodiment.

[0030] The housing 3, i.e. the base part 31 and the cover part 32, preferably comprises or consists of plastic. Particularly preferably, the housing 3, i.e. particularly preferably plastic, has high temperature stability and high breakdown voltage. Furthermore, it is advantageous if the housing 3, i.e. particularly preferably plastic, has a high thermal conductivity. Furthermore, the housing 3, i.e. particularly preferably plastic, can have high mechanical strength in order to have sufficient stability against mechanical loads during operation.

[0031] The plastic is preferably a thermoplastic. In particular, the housing 3 comprises or consists of a plastic based on LCP. Particularly preferably, an LCP is used whose starting polymer can be processed by a shaping process, i.e. for example by injection moulding or extrusion moulding. The plastic further comprises a filler which, in the illustrated embodiment, is boron nitride. Correspondingly, the base part 31 and the cover part 32 comprise or consist of a plastic which is formed by a thermoplastic strongly crosslinked with boron nitride, particularly preferably an LCP.

[0032] Depending on the materials used, the sensor device 100 is adapted and designed to be arranged in the vicinity of, in indirect contact with, or preferably in direct contact with, an electrical consumer.

[0033] Particularly preferably, all materials of the sensor device 100, i.e. the housing 3, the sensor element 1, and the capsule, wire connection 2 and electrical conductor 4 of the sensor element 1, and the material of the potting compound 33, have high temperature stability. As explained in the general part, the materials of the sensor device 100 are selected such that the sensor device 100 can be used in an electrical device in which there can be an operating temperature in which, during its operation, it is preferably in the temperature range from -40 °C to 200 °C. Furthermore, the sensor device 100 has a high breakdown voltage. Particularly preferably, the sensor device 100 is adapted and designed to be operated in the vicinity of, in indirect contact with, or preferably in direct contact with, a surface which can have a voltage of up to 2500 V. Furthermore, the sensor device 100 has a short response time with t63 < 5 s for a temperature jump between 25 °C and 85 °C.

[0034] Furthermore, the sensor device 100 has a mechanical fixing element 7. The mechanical fixing element is formed as a metal spring element. By means of the mechanical fixing element 7, the fixing of the sensor device 100 to a mounting element, in particular to a mounting element of an electrical consumer, can be achieved as will be explained in more detail below.

[0035] In particular, the mechanical fixing element 7 can be formed as a metal clip comprising or consisting of stainless steel such as CrNi steel. The mechanical fixing element 7 is fixed to the housing 3, in the illustrated embodiment particularly to the base part 31. For example, a part of the mechanical fixing element 7 can be deformed from a part of the housing 3 and / or the mechanical fixing element 7 can enclose a part of the housing 3, so that the mechanical fixing element is permanently and stably connected to the housing 3. As can be recognized, for example, in FIGS. 1A, 1C and 1E, a part of the mechanical fixing element 7 encloses a part of the base part 31. The base part 31 has, for this purpose, a corresponding support surface 34 on the side opposite to the lower surface 35. When the sensor device 100 is pushed onto the mounting element, as will be further explained below, the mechanical fixing element 7 generates a clamping force, whereby the sensor device 100 can be securely held. In particular, the mounting element is clamped between the lower surface 35 of the housing 3 and the mechanical fixing element 7, as is further shown, for example, in FIG. 4A below.

[0036] Furthermore, the mechanical fixing element 7 has a latching element 70. The latching element 70 can be formed as a latching nose, as shown, and can engage with a latching counter-element of the mounting element in the form of a window when the sensor device is mounted on the mounting element, so that reliable fixing of the sensor device to the mounting element can be ensured even under mechanical loads.

[0037] Furthermore, the housing 3, in the illustrated embodiment particularly the base part 31, has at least one mounting guide element 36. As can be recognized particularly in FIG. 1D, the base part 31 has a double guide groove 38 with an insertion ramp 39 and a chamfer 37 on one side as the mounting guide element 36. As will be explained further below, the mounting element on which the sensor device 100 is mounted likewise has a chamfer on one side, formed as a counter-piece to the chamfer 37 on one side of the housing 3.

[0038] FIG. 2A shows an electric device 200 having a sensor device 100 as described in the previous embodiment. Further, the electric device 200 has an electric consumption part 20 on which the sensor device 100 is directly disposed and fixed. The electric consumption part 20 can particularly preferably be an electric motor. The electric device 200, particularly the electric consumption part 20, has a mounting element 8 which will be described in more detail in relation to FIGS. 3A and 3B, and the sensor device 100 is disposed and fixed on the mounting element 8. Due to the above-described elastic restoring force of the mechanical fixing element of the sensor device 100, permanent contact with the mounting element 8 is ensured, and as a result, the surface temperature of the mounting element 8 can be accurately grasped.

[0039] In the illustrated embodiment, the mounting element 8 is part of a bus bar 21, for example a copper rail, of the electric consumption part 20. Alternatively, the mounting element 8 can also be fixed to the bus bar 21 of the electric consumption part 20. Correspondingly, the mounting element 8 can have at least one voltage and / or current can flow through the mounting element 8, at least during the operation of the electric consumption part 20 itself.

[0040] FIG. 2B shows a vehicle 1000 having the electric device 200. Thus, the vehicle 1000 has the sensor device 100 and the electric consumption part 20, particularly an electric motor. The vehicle 1000 can be a road vehicle, a rail vehicle, a ship or an aircraft. Particularly preferably, the vehicle 1000 is a motor vehicle as shown.

[0041] Figures 3A and 3B show an embodiment of the attachment element 8 in a top view and a side view. The attachment element 8 can be formed, as shown, 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 attachment element 8 has a push-in area 80 that conforms to the area formed by the attachment guide element 36 on the lower surface 35 of the housing 3 of the sensor device 100 shown in FIGS. 1A - 1H. By means of the connection area 83, the attachment element 8 can be fixed to the electrical consumer, i.e., for example, to a bus bar as described above. Alternatively, the connection area 83 can be part of a bus bar. The arrangement of the push-in area 80 bent or folded, for example, at an angle of approximately 45° with respect to the connection area 83 can enable easier attachment of the sensor device 100 to the electrical consumer.

[0042] As a counterpart to the latch element 70 of the mechanical fixing element 7 of the sensor device 100, the attachment element 8 has a latch counter element formed as a window in the illustrated embodiment. The latch element of the sensor device formed as a latch nose can fit into the latch element.

[0043] Furthermore, the attachment element 8 has a chamfer 82 on one side, formed as a counterpart to the chamfer 37 on the lower surface 35 of the housing 3 of the sensor device 100.

[0044] In FIG. 4A, the sensor device 100 is shown arranged on the attachment element 8 and fully pushed in. Due to the latch element of the sensor device 100 and the latch counter element of the attachment element 8, as well as the clamping force of the mechanical fixing element of the sensor device, a reliable and mechanically loadable fixation of the sensor device 100 onto the attachment element 8 can be achieved.

[0045] As shown in FIG. 4B, an incorrect and unintended attachment of the sensor device 100 onto the attachment element 8 can be easily avoided by attachment guiding elements, in particular by chamfers on one side of the lower surface of the sensor device and corresponding chamfers on one side of the attachment element 8. Thus, guiding during attachment and anti-rotation during attachment can be achieved by the attachment guiding elements of the sensor device 100. Furthermore, by additionally bending the attachment element 8, easy recognition of the correct attachment direction can be made possible.

[0046] Features and examples described in connection with the drawings can be combined with one another according to further examples, even if not all combinations are explicitly described. Furthermore, the examples described in connection with the drawings can alternatively or additionally have further features according to the description of general parts.

[0047] The present invention is not limited by the description based on examples. Rather, the present invention includes all combinations of features, including all new features and in particular all combinations of features in the claims, even if such features or combinations themselves are not explicitly presented in the claims or examples.

Description of Reference Numerals

[0048] 1 Sensor element 2 Wire connection part 3 Housing 4 Electrical conductor 5 Cable sleeve 7 Mechanical fixing element 8 Attachment element 20 Electrical consumption part 21 Bus bar 30 Cavity 31 Base part 32 Cover part 33 Potting material 34 Support surface 35 Lower surface 36 Attachment guiding element 37 Chamfer 38 guide groove 39 insertion slope 70 latch element 80 insertion area 81 latch counter element 82 chamfered portion 83 connection area 100 sensor device 200 electrical device 1000 vehicle

Claims

1. A sensor device (100) having a sensor element (1) within a housing (3), wherein a mechanical fixing element (7) having a spring element is arranged and fixed to the housing, the housing comprising a plastic containing a liquid crystal polymer filled with boron nitride, a sensor device.

2. The sensor device according to claim 1, wherein the sensor element is a temperature sensor element.

3. The sensor device according to claim 1 or 2, wherein the mechanical fixing element has a latch element (70).

4. The sensor device according to any one of claims 1 to 3, wherein the housing has at least one mounting guide element (36), and the mounting guide element is selected from one or more insertion slopes (39), one or more guide grooves (38), and one or more chamfered portions (37).

5. The sensor device according to any one of claims 1 to 4, wherein the housing has a base portion (31) and a cover portion (32) connected to each other, and a cavity (30) therein where the sensor element is arranged and at least partially filled with a potting material of gas or epoxy resin.

6. A sensor device (100) having a sensor element (1) within a housing (3), the housing comprising a plastic containing a liquid crystal polymer filled with boron nitride, a sensor device.

7. An electrical device (200) having the sensor device according to any one of claims 1 to 6 and an electrical consumption part (20), wherein the sensor device is arranged on the electrical consumption part and fixed by a clamping force via the mechanical fixing element (7).

8. The electrical device according to claim 7, wherein the electrical consumption part is an electric motor.

9. The electrical device according to claim 7 or 8, wherein the electrical consumption part has a mounting element (8), and the sensor device is arranged and fixed on the mounting element (8).

10. The electrical device according to claim 9, wherein the mounting element is a part of a bus bar (21) of the electrical consumption part.

11. The electrical device according to claim 9 or 10, wherein the mounting element is formed in the form of a metal tongue, and the sensor device is pushed onto it.

12. The electrical device according to any one of claims 9 to 11, wherein the attachment element has a latch counter element (81), and a latch element (70) of the mechanical fixing element is fitted into the latch counter element (81).

13. The electrical device according to any one of claims 9 to 12, wherein the attachment element has a chamfered portion (82) on one side, which is formed as a counter piece for the chamfered portion (37) on one side of the housing.

14. A vehicle (1000) having the electrical device (200) according to any one of claims 7 to 13.

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