Foam-Encapsulated Handle Sensor Module for Easy Sealed Assembly
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Solution Overview
Problem
Existing handle modules for vehicles lack a compact and easily assembled electronic sensor module that can effectively protect sensor elements from environmental influences while maintaining reliable operation.
Innovation Solution
The electronic sensor module incorporates a movable sensor element encapsulated in foam material, which serves as a connecting, resetting, and sealing component, and is designed as a preassembly unit for simplified assembly and protection from moisture and other environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sensor module uses separate assembly of sensor elements and electronics unit, then the assembly process becomes complex and time-consuming, but disassembling into separate components allows for easier manufacturing and delivery
Solution Approach 1:
The sensor module is divided into a preassembly unit containing the movable sensor element and foam material, and a separate electronics unit. This segmentation allows independent manufacturing and delivery of components while maintaining a relatively simple final assembly process through the connection elements that protrude from the foam material.
Solution Approach 2:
The movable sensor element is pre-assembled with the foam material and connection elements are prepared in advance protruding from the foam. This preliminary preparation enables simplified final assembly where the preassembly unit is simply connected to the electronics unit without requiring complex assembly steps on-site.
2Device complexity
If the movable sensor element is exposed to the environment, then the structure remains simple, but the sensor element is vulnerable to moisture, rain, and dirty water
Solution Approach 1:
The foam material encapsulates the movable sensor element, creating a protective barrier against environmental influences such as moisture, rain, and dirty water. The foam acts as a flexible sealing material that shields the sensor element while allowing it to maintain its sensing functionality.
Solution Approach 2:
The combination of foam material and movable sensor element creates a composite structure where the foam provides environmental protection while the sensor element maintains its sensing capability. This composite approach protects the sensor without requiring complex separate sealing mechanisms.
3Adaptability or versatility
If multiple separate components are used for mounting, resetting, and sealing the sensor element, then each function can be optimized independently, but the number of components and assembly steps increases
Solution Approach 1:
The foam material is designed to perform multiple functions simultaneously: it seals the movable sensor element against environmental influences, provides mounting support through connection elements, and enables resetting functionality. This multi-functional approach reduces the number of separate components needed while maintaining all necessary functions.
Solution Approach 2:
The sealing function, mounting function, and resetting function are merged into a single integrated foam material structure. Instead of using separate components for each function, the foam material combines all these functions into one element, simplifying the overall device structure and reducing assembly 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
This solution provides a compact, easily assembled sensor module that is protected from environmental influences, ensuring reliable operation and reducing the complexity of assembly processes.
Implementation Method 1
at least the movable sensor element is encapsulated at least in some regions by means of a foam material
Implementation Method 2
such a resilient material is provided as the foam material that the movable sensor element is additionally resiliently mounted
Data Source
AI summary
An electronic sensor module for a handle may have one sensor unit having a movable sensor element and a fixed sensor element which is arranged spaced apart from and opposite the movable sensor element. The module may also have an electronics unit which is electrically connected to the sensor elements for triggering a switching signal and on which the fixed sensor element is arranged. At least the movable sensor element may be encapsulated at least in some regions by a foam material and is designed as an integrated component in the form of a preassembly unit. Connection elements of the movable sensor element protrude from the foam material in a preassembly state and are connected to the electronics unit in an assembled state. A handle module and to a movable vehicle element are also described.