Magnetic Field Sensor Undercut Contact Fixation
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Solution Overview
Problem
Existing magnetic field sensors face challenges in secure fixation during the injection molding process with plastic materials, leading to potential displacement and reduced production quality.
Innovation Solution
Incorporating band-shaped electrical contact elements with undercut sections that form a spatially form-fitting connection with a support during the injection molding process, ensuring secure fixation and positioning of the magnetic field sensor in three axes of a Cartesian coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical contact elements are used during injection molding, then the injection molding process can proceed, but the magnetic field sensor may be displaced and fixation reliability deteriorates
Solution Approach 1:
The undercut sections are pre-formed on the electrical contact elements before the injection molding process. This preliminary structural preparation enables the contact elements to automatically engage with corresponding features on the support and magnetic field sensor, ensuring precise positioning and secure fixation are established before the molding process begins, thereby preventing displacement during injection.
2Reliability
If additional fixing structures are added to secure the magnetic field sensor, then fixation reliability improves, but device complexity increases
Solution Approach 1:
The electrical contact elements serve multiple functions: they provide electrical contact with the magnetic field sensor, provide mechanical support, and through their undercut sections, provide secure fixation during injection molding. By integrating these multiple functions into a single component, the invention achieves reliable fixation without adding separate fixing structures, thereby avoiding increased device complexity.
3Manufacturing precision
If the magnetic field sensor is securely fixed during handling and injection molding, then production quality improves, but the device complexity increases
Solution Approach 1:
The invention merges the electrical contact function and the mechanical fixation function into a single integrated component - the electrical contact element with undercut sections. This consolidation eliminates the need for separate fixing mechanisms while ensuring the magnetic field sensor remains securely positioned during handling and injection molding, thereby improving production quality without increasing device complexity.
Data Source
AI summary
Magnetic field sensor having a magnetic field sensor element and at least a band-shaped electrical contact element, in which the at least one contact element has at least one undercut section to fix in spatially form-fitting manner the magnetic field sensor at a support during the at least sectional injection molding process with a plastic material. Magnetic field sensor module, the magnetic field sensor module comprising a support with at least a fixing section for a magnetic field sensor and a plastic injection molding, wherein the magnetic field sensor module has at least such a magnetic field sensor and the magnetic field sensor is spatially fixed in form-fitting manner with its at least one undercut section at the at least one fixing section of the support and is injection molded with plastic material at least in sections, and a method for producing such a magnetic field sensor module, wherein the method comprises the following steps: correctly positioned arrangement of the at least one magnetic field sensor at the support, wherein the at least one magnetic field sensor with its at least one undercut section is arranged at the at least one fixing section, which has not yet been reshaped; reshaping the at least one fixing section to fix in spatially form-fitting manner the at least one magnetic field sensor at the support; injection molding the support at least in sections and/or the magnetic field sensor with plastic material.