Capacitive Sensor Unit With Plastic Carrier for Harsh Vehicle Mounting
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Solution Overview
Problem
Existing sensor units for contactless actuation of vehicle flaps are prone to damage from external environmental influences such as water and stone chips, leading to operational failures, and lack versatility for various vehicle types and equipment.
Innovation Solution
A sensor unit with a capacitive sensor element and a plastic carrier element that partially envelops the wire, featuring a modular design with sections that can be connected and fastened using various holding and fastening means, providing protection and adaptability to different vehicle geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flat, electrically conductive strips or foils are used as sensors, then the sensor field is optimally designed to detect object approach through capacitive change, but the sensors are damaged by splash water and stone chips, rendering them inoperable
Solution Approach 1:
The patent replaces rigid flat strips or foils with a flexible wire arranged on a carrier element. This wire configuration is more resistant to mechanical damage from stone chips and splash water while maintaining the capacitive sensing function. The flexible nature of the wire allows it to better withstand environmental stresses compared to rigid flat conductive elements.
Solution Approach 2:
The sensor unit employs a composite structure combining a conductive wire with a non-conductive carrier element. This composite design integrates the electrical functionality of the wire with the mechanical protection and structural support of the carrier, creating a sensor that is both functional and durable in harsh environments.
2Ease of operation
If sensors are located in critical areas of a vehicle exposed to heavy soiling, stone chips, and water jets, then the sensor unit can be installed in optimal positions for detection, but the sensors are damaged by external influences
Solution Approach 1:
The flexible wire-on-carrier construction allows the sensor to be installed in critical areas while being protected from environmental damage. The flexible structure can conform to various mounting surfaces and is inherently more resistant to mechanical impacts from stone chips and water jets compared to rigid flat sensors.
Solution Approach 2:
The carrier element serves as a protective structure that shields the conductive wire from direct exposure to harmful environmental factors. This pre-protective design allows the sensor to be installed in locations that would otherwise be too exposed, cushioning the sensitive electrical component from mechanical damage before it occurs.
3Adaptability or versatility
If a modular design with sections is used, then the sensor unit can be easily adapted to various vehicle types and equipment, but the device complexity increases
Solution Approach 1:
The sensor unit is divided into multiple sections along the carrier element, allowing individual sections to be selectively used or removed. This segmentation enables easy adaptation to different vehicle types and equipment configurations while keeping the overall design relatively simple, as each section is a standardized unit that can be combined in various ways.
Solution Approach 2:
The modular sections are designed with universal mounting capabilities that allow them to be adapted to various vehicle types and equipment. Each section can serve multiple functions depending on its installation location and configuration, reducing the need for specialized components for different applications and thereby limiting the increase in device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the sensor unit's durability and versatility, allowing it to withstand harsh environmental conditions and easily adapt to various vehicle configurations, ensuring reliable and long-term operation.
Implementation Method 1
capacitive sensors are used as proximity sensors in the corresponding sensor unit, which expediently have a wide-area electrode. Wide-area electrodes have the advantage that the sensor field is optimally designed to detect the approach of an object, in particular in the form of a user's leg, through a capacitive change at the sensor.
Data Source
Figure 1~1b
Figure 2~2b
Figure 3~4b
AI summary
The invention relates to a sensor unit (10) for the contactless actuation of an actuator (102), in particular a flap (101) or the like of a vehicle (100), comprising at least one capacitive sensor element (11, 12), wherein the sensor element (11, 12) has a wire (13) arranged on a carrier element (14). According to the invention, the carrier element (14) is at least partially made of plastic. Furthermore, the invention also relates to a safety system (110) for the contactless opening and/or closing of a flap (101) of a vehicle (100) or the like, comprising at least one sensor unit (10) according to the invention. The invention also relates to a method for manufacturing a sensor unit (10) according to the invention.