Capacitive Hatch Sensor With Nested Wire Protection
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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 insufficient protection.
Innovation Solution
A sensor unit with a capacitive sensor element featuring an electrically conductive core capacitively coupled to a wire, where the wire is arranged on a carrier element that serves as both a housing and a protective layer, enhancing metrological properties and resistance to environmental influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wide electrodes are used to optimize sensor field and improve measurement results, then measurement precision is improved, but device complexity and vulnerability to external damage increase
Solution Approach 1:
The wire is nested within the carrier element, with the carrier element serving as a protective housing that encloses the wire. This nested structure allows the sensor to achieve both wide measurement coverage and robust protection against external mechanical influences like stone chips and water jets.
Solution Approach 2:
The carrier element acts as a protective shell or housing that encloses the wire. This shell structure provides mechanical protection while maintaining the capacitive sensing function, effectively shielding the sensitive wire from environmental hazards.
2Ease of operation
If sensors are placed in critical areas exposed to heavy soiling and stone chips, then ease of operation is improved, but reliability deteriorates due to damage from splashing water and stone chips
Solution Approach 1:
The wire is nested within the carrier element, with the carrier element serving as a protective housing that encloses the wire. This nested structure allows the sensor to achieve both wide measurement coverage and robust protection against external mechanical influences like stone chips and water jets.
Solution Approach 2:
The carrier element provides beforehand protection to the wire against mechanical damages such as stone chips and water jet impacts. This protective housing is designed to absorb or deflect harmful external influences before they can reach the sensitive wire inside.
3Device complexity
If the wire is directly electrically connected to the electrically conductive core, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The carrier element serves as an intermediary between the wire and the electrically conductive core, providing capacitive coupling without direct electrical contact. This intermediary approach simplifies the overall structure while maintaining precise electrical characteristics through the capacitive interface.
4Reliability
If additional protective structures are added to protect the wire, then reliability is improved, but device complexity increases
Solution Approach 1:
The carrier element performs multiple functions simultaneously: it serves as a protective housing for the wire, provides the electrically conductive core for capacitive sensing, and acts as the structural support for the entire sensor unit. This multi-functionality reduces overall device complexity while maintaining robust protection.
Solution Approach 2:
The protective housing, conductive core, and structural support functions are merged into a single integrated carrier element. This consolidation eliminates the need for separate protective structures, reducing device complexity while ensuring comprehensive protection against external mechanical influences.
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 provides a robust and inexpensive sensor unit with improved measuring capabilities, ensuring permanent operation in harsh environments by protecting the capacitive sensor elements from mechanical and environmental hazards.
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 actuating an actuating element (102), in particular a hatch (101) or similar of a vehicle (100), without contact, comprising at least one capacitive sensor element (11, 12), wherein the sensor element (11, 12) has a wire (13), which is arranged on a support element (14). The support element (14) has at least one electrically conductive core (18). The invention also relates to a security system (100), in particular, for opening and/or closing a hatch (101) of a vehicle or similar without contact, comprising at least one such sensor unit (10). The invention also relates to a method for producing such a sensor unit (10).