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 therefore must 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 variations 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 may strengthen 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 objective is achieved by the subject matter of patent claims 1 and 4.

[0007] Other advantageous designs and embodiments are the subject of the dependent claims.

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

[0009] Therefore, according to the present invention, a method for manufacturing a sensor module comprising at least a sensor head, a metal cover, a connector module, and a connector element is proposed, according to the following steps: - Steps include providing a connector element and a metal cover, - A step of attaching a connector element to a metal cover, wherein the connector element has a molten material on a surface facing the metal cover in at least a partial area, and the metal cover has an area on a surface facing the connector element where the molten material of the connector element is applied, - A step of heating a metal cover on the side opposite to the connector element, wherein the molten material melts as a result of the heating, - A step of establishing a connection with a molten material in at least an area provided on the metal cover between the connector element and the metal cover, - Step of securing the sensor head to the metal cover.

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

[0011] In the proposed method, the connector element is pressed into a metal cover, the molten material is directly above the area of ​​the metal cover, and the material and the area of ​​the metal cover have substantially the same geometric shape. Meanwhile, the metal cover is heated on the side opposite to the connector element to melt the molten material. After melting, the molten material flows into the area for which it is intended, 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 sector.

[0013] In a preferred design, a structure is provided into which molten material flows to establish a connection over the area of ​​the metal cover. This structure is particularly advantageous because such a structure has, for example, grooves or recesses into which liquid material can flow. This has the advantage of establishing a more robust connection between the connector element and the metal cover.

[0014] Preferably, the metal cover is heated by a laser, a heating plate, or by induction. These methods are conspicuously preferred methods for ensuring that the metal cover is heated particularly evenly and quickly.

[0015] Furthermore, according to the present invention, a sensor module is proposed comprising at least a sensor head, a metal cover, a connector module, and a connector element, wherein the connector element has a molten material on the surface facing the metal cover in at least a partial area, and the metal cover has an area on the surface facing the connector element in at least a partial area where the molten material is applied, and each of the connector element and the metal plate has a central recess into which the connector module can be inserted, and 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 molten material on the area of ​​the metal cover.

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

[0017] In the proposed method, the connector element is pressed into a metal cover, the molten material is directly above the area of ​​the metal cover, and the material and the area of ​​the metal cover have substantially the same geometric shape. Meanwhile, the metal cover is heated on the opposite side from the connector element to melt the molten material. After melting, the molten metal flows into the area intended for it, thus establishing a connection between the metal cover and the connector element.

[0018] The metal cover is made of, for example, aluminum alloy AL99.5. However, other materials are also possible.

[0019] The connector module can have all the common connector interfaces relevant to the automotive sector.

[0020] In a particularly preferred embodiment, the area of ​​the metal cover is designed so that a molten material flows into the structure, establishing a connection 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 liquid material can flow. This is advantageous because it establishes a more robust connection between the connector element and the metal cover.

[0021] Particularly preferably, the structure of the metal cover area is fabricated using a laser, or by punching or turning. These methods are preferred material processing methods that allow for particularly easy construction of the metal cover within a given area. Other metalworking methods that can fabricate the structure may also be considered.

[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 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] A schematic flow chart of a method according to one embodiment of the present invention is shown. [Figure 2a] A schematic representation of a connector element according to one embodiment of the present invention is shown. [Figure 2b] Another schematic representation of a connector element according to another embodiment of the present invention is shown. [Figure 3a] A schematic representation of a metal cover according to one embodiment of the present invention is shown. [Figure 3b] Another schematic representation of a metal cover according to another embodiment of the present invention is shown. [Figure 4] A schematic representation of a connector element combined with a metal cover according to one embodiment of the present invention is shown. [Figure 5] A schematic representation of a sensor module according to one embodiment of the present invention is shown. [Modes for carrying out the invention]

[0029] Figure 1 shows a schematic flowchart 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, and the connector element 2 has a molten material 5 on a surface 2a facing the metal cover 3 in at least a partial area, and the metal cover 3 has a region F on a surface 3a facing the connector element 2 in at least a partial area where the molten 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 molten material 5 melts due to the heating. In step S4, a connection is established between the connector element 2 and the metal cover 3, and the metal cover is provided with the molten material 5 in at least region F. In step S5, the sensor head 6 is fixed to the metal cover 3.

[0030] Figures 2a and 2b show schematic representations of a connector element according to one embodiment of the present invention. The connector element 2 in Figure 2a has a molten material 5 on the surface 2a facing the metal cover. Furthermore, in the design shown in Figure 2a, the connector module 4 is already incorporated into the connector element 2. The representation in Figure 2b substantially corresponds to Figure 2a, however, in Figure 2b, the connector module 4 is not located inside the connector element 2, and only the recess A2 is present in Figure 2b.

[0031] Figures 3a and 3b show schematic representations of a metal cover according to one embodiment of the present invention. In the representation in Figure 3a, the metal cover 3 has a region F on the surface 3a facing the connector element to which the fusible material 5 of the connector element 2 is applied. This region F may have a structure to enhance the durability of the connection. A recess A3 into which the connector module 4 can be inserted is shown in the center of the metal cover 3. The representation in Figure 3b substantially corresponds to Figure 3a, except that in Figure 3b, the sensor module 4 is located within the recess A3 of the metal cover 3.

[0032] Figure 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 molten material 5 is visible between the connector element 2 and the metal cover 3. The metal cover 3 is heated to a high temperature T on the side 3b opposite to the connector element 2, causing the molten material 5 to melt.

[0033] Figure 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 molten material 5 and a metal cover 3, the metal cover 3 having an area F thereon to which the molten material 5 is applied. Furthermore, in this embodiment, a connector module 4 is located inside the metal cover 3. As already shown, the connector module 4 may also be located inside the connector element 2, after which the connector element 2 is connected to the metal cover 3. Furthermore, the sensor module 1 is provided with a sensor head 6, which is connected to the metal cover 3. While this application relates to the invention described in the claims, it also includes the following other aspects. 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), wherein: - Step (S1) of providing the connector element (2) and the metal cover (3), - Step (S2) of attaching the connector element (2) to the metal cover (3), wherein the connector element (2) has a molten material (5) on a surface (2a) facing the metal cover (3) in at least a partial area, and the metal cover (3) has an area (F) on a surface (3a) facing the connector element (2) where the molten material (5) of the connector element (2) is applied, - A step of heating the metal cover (3) on the side (3b) opposite to the connector element (2), wherein the molten material (5) melts as a result of the heating, - Step (S4) of establishing a connection between the connector element (2) and the metal cover (3) with the molten material (5) in at least the area (F) provided on the metal cover (3), - Step (S5) of fixing the sensor head (6) to the metal cover (3), A method that includes this. 2. The method according to the present invention, characterized in that a structure is provided into which the molten molten material (5) flows in order to establish the connection on the area (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) comprising 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 molten material (5) on a surface (2a) facing the metal cover (3) in at least a partial area, the metal cover (3) has an area (F) on a surface (3a) facing the connector element (2) where the molten material (5) is applied, 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 the melting of the molten material (5) on the area of ​​the metal cover (3). 5. The sensor module (1) according to 4 above, characterized in that the area (F) of the metal cover (3) has a structure, and the molten 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 item 5, characterized in that the structure of the area (F) of the metal cover (3) is manufactured by punching or turning using a laser. 7. The sensor module (1) according to 5 or 6, characterized in that the area (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 the above 4, characterized in that the molten material (5) is arranged in the form of a ring on the connector element (2) around the recess (A2) for the connector module (4). 9. The sensor module (1) according to any one of 4 to 8 above, characterized in that when connecting the metal cover (3) to the connector element (2), the connector module (4) is positioned on the metal cover (3) or inside the connector element (2). 10. The sensor module (1) according to the above 4, characterized in that the molten material (5) is plastic. [Explanation of Symbols]

[0034] 1 Sensor Module 2 Connector elements 2a Surface facing the metal cover 3 Metal cover 3a The surface facing the connector element 3b The side opposite to the connector element 4 Connector Modules 5. Meltable materials 6 Sensor Heads A2 Recess of connector element A3 Metal cover recess 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 following steps: - Step (S1) of providing the connector element (2) and the metal cover (3), - Step (S2) of attaching the connector element (2) to the metal cover (3), wherein the connector element (2) has a molten material (5) on a surface (2a) facing the metal cover (3) in at least a partial area, and the metal cover (3) has an area (F) on a surface (3a) facing the connector element (2) where the molten material (5) of the connector element (2) is applied, and each of the connector element (2) and the metal cover (3) has a central recess (A2, A3) into which the connector module (4) is inserted, - A step of heating the metal cover (3) on the side (3b) opposite to the connector element (2), wherein the molten material (5) melts as a result of the heating, - Step (S4) of establishing a connection between the connector element (2) and the metal cover (3) with the molten material (5) in at least the area (F) provided on the metal cover (3), - Step (S5) of fixing the sensor head (6) to the metal cover (3), A method that includes this.

2. The method according to claim 1, characterized in that a structure is provided into which the molten molten material (5) flows in order to establish the connection on the area (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) comprising at least a sensor head (6), a metal cover (3), a connector module (4), and a connector element (2), The connector element (2) has a molten material (5) on the surface (2a) facing the metal cover (3) in at least a partial area. The metal cover (3) has an area (F) in which the molten material (5) is applied to the surface (3a) facing the connector element (2) in at least a partial area. The connector element (2) and the metal cover (3) each have a central recess (A2, A3) into which the connector module (4) can be inserted. By heating the metal cover (3), the connection between the connector element (2) and the metal cover (3) is established as a result of the melting of the molten material (5) on the area of ​​the metal cover (3). The sensor head (6) is connected to the metal cover (3). Sensor module (1).

5. The sensor module (1) according to claim 4, characterized in that the area (F) of the metal cover (3) has a structure, and the molten 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 area (F) of the metal cover (3) is manufactured by punching or turning using a laser.

7. The sensor module (1) according to claim 5 or 6, characterized in that the area (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 molten material (5) is arranged in the form of a ring on the connector element (2) around the recess (A2) for the connector module (4).

9. The sensor module (1) according to claim 4 or 5, characterized in that when the metal cover (3) is connected to the connector element (2), the connector module (4) is positioned on the metal cover (3) or inside the connector element (2).

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

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