Force Sensor Group Sealing with Composite Materials
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Solution Overview
Problem
Existing force sensors for motor vehicles face challenges in withstanding harsh environments, including high temperatures, brake dust, water spray, stone impacts, and chemical exposure, while maintaining functionality and requiring costly and precise sealing methods.
Innovation Solution
A method for constructing a force sensor group involves integrating force sensor elements into an expansion body, electrically connecting it to a printed circuit board, protecting the connections with a potting compound, and media-tight overmolding to seal and protect the components from mechanical and chemical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sealing methods using thermoplastics with laser welding are used, then mechanical stress protection is improved, but manufacturing cost increases and manufacturing precision requirements increase
Solution Approach 1:
The patent uses a two-component sealing system combining thermoplastic material for mechanical strength and silicone rubber for chemical resistance. This composite approach allows each material to contribute its superior properties, achieving both mechanical stress protection and chemical resistance without requiring expensive single-material solutions or complex laser welding processes
Solution Approach 2:
The sealing function is divided into two distinct components: an outer thermoplastic sealing element for mechanical protection and an inner silicone rubber sealing element for chemical resistance. This segmentation allows each component to be optimized independently and manufactured separately, reducing overall manufacturing complexity and cost
2Strength
If sealing methods using thermoplastics with laser welding are used, then mechanical stress protection is improved, but manufacturing precision requirements increase
Solution Approach 1:
By dividing the sealing function into two separate elements (thermoplastic outer seal and silicone rubber inner seal), each component can be manufactured with standard tolerances and assembled together. This eliminates the need for high-precision laser welding of a single complex sealing structure, as each segmented component has simpler geometric requirements
Solution Approach 2:
The thermoplastic sealing element acts as an intermediary structural component that provides mechanical mounting and positioning, while the silicone rubber sealing element provides the actual chemical-resistant seal. This intermediary structure simplifies the precision requirements by separating structural support from sealing function
3Strength
If conventional seals are used, then mechanical stress protection is provided, but chemical resistance is insufficient
Solution Approach 1:
The patent combines thermoplastic material (providing mechanical strength and structural integrity) with silicone rubber material (providing superior chemical resistance). This composite sealing system ensures that the force sensor is protected from both mechanical stresses and chemical exposure in harsh automotive environments
Solution Approach 2:
Different regions of the sealing system have different material properties optimized for their specific functions: the outer thermoplastic region provides mechanical strength and environmental protection, while the inner silicone rubber region provides chemical resistance where it contacts potential contaminants. This local optimization of material properties addresses both mechanical and chemical protection requirements
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 method provides a robust and durable force sensor group that is efficiently sealed against chemicals and optimally protected from mechanical stress, ensuring reliable operation in harsh environments while reducing manufacturing costs.
Implementation Method 1
protecting the electrical connections by applying a potting compound to the electrical connections
Implementation Method 2
media-tight overmolding of the printed circuit board and at least sections of the expansion body to seal the electronic components and the force sensor elements
Data Source
AI summary
A method for constructing a force sensor group is provided. An expansion body is provided that has integrated force sensor elements. A printed circuit board is provided having electronic components that are configured to receive measurement signals from the force sensor elements. The printed circuit board is electrically connected to the force sensor elements of the expansion body. The electrical connections are protected by applying a potting compound to the electrical connections. Media-tight overmolding of the printed circuit board is performed and at least sections of the expansion body to seal the electronic components and the force sensor elements or to seal and to mechanically protect the electronic components and the force sensor elements.