Capacitive Sensor Unit With Protected Wire-Core Coupling
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Solution Overview
Problem
Existing sensor units for contactless actuation of vehicle flaps are prone to damage from external mechanical influences such as splashing water and stone chips, leading to functional failures due to inadequate protection.
Innovation Solution
A sensor unit with a capacitive sensor element featuring an electrically conductive core capacitively coupled to a wire, which is arranged on a carrier element providing insulation and protection, eliminating the need for direct electrical connection and reducing vulnerability to environmental hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flat electrically conductive strips or films are used as sensors, then the sensor field is optimally designed to detect object approach, but the sensors are vulnerable to damage from external mechanical influences such as splashing water and stone chips
Solution Approach 1:
The patent applies this principle by using a wire wrapped around a carrier element, where the carrier element acts as a protective flexible structure that shields the wire from external mechanical influences while maintaining the capacitive sensing function. The carrier element provides physical protection against water jets and stone chips while the wire maintains the sensor field for detecting object approach.
2Reliability
If the wire is directly electrically connected to the electrically conductive core, then electrical connection is achieved, but critical weak points are created that are vulnerable to damage
Solution Approach 1:
The patent applies this principle by introducing the carrier element as an intermediary between the wire and the electrically conductive core. The carrier element provides mechanical support and protection while the wire is wrapped around it, eliminating the need for direct electrical connections or contact points that would create vulnerability to damage from water and stone chips.
3Measurement precision
If wide electrodes are used to improve measurement results, then the measuring range is extended, but the sensor unit becomes more complex and costly to manufacture
Solution Approach 1:
The patent applies this principle by transitioning from flat two-dimensional electrodes to a three-dimensional wire-wrapped-around-carrier-element structure. This dimensional change allows the sensor to achieve an extended measuring range through the spatial arrangement of the wire around the carrier element, while maintaining a simple and cost-effective manufacturing process.
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 ensures robust and inexpensive sensor units with enhanced metrological properties, capable of withstanding harsh environments and maintaining functionality in exposed conditions, while reducing manufacturing costs and eliminating critical weak points.
Implementation Method 1
the electrically conductive core is capacitively coupled to the wire of the carrier element. Thus, the wire and the electrically conductive core together form the capacitive sensor element
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) has at least one electrically conductive core (18). 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.