Molded Sensor Carrier with Exposed SMD Resistor Contacts
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Solution Overview
Problem
Existing methods for producing electrical sensors, particularly temperature sensors, are complex and lack automation, making them difficult to miniaturize and manufacture efficiently.
Innovation Solution
A method involving a carrier element with a wireless SMD measuring resistor, where the resistor is partially covered and held by a molded plastic part, allowing for electrical connection via exposed surfaces and guide channels, eliminating the need for printed circuit boards and conductor tracks, and enabling automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a printed circuit board with conductor tracks and terminal blocks is used to connect the measuring resistor, then electrical connections can be established, but the device complexity and manufacturing complexity increase significantly
Solution Approach 1:
The patent extracts and eliminates the printed circuit board, terminal blocks, and conductor tracks from the sensor structure. Instead, it uses a molded plastic part with integrated guide channels and contact fields that directly guide connecting wires to the measuring resistor, thereby removing unnecessary intermediate components while maintaining reliable electrical connections.
Solution Approach 2:
The molded plastic part serves multiple functions simultaneously: it provides structural support, guides connecting wires through integrated channels, positions the measuring resistor, and establishes electrical contacts. This multi-functional design replaces the separate functions previously performed by the printed circuit board, terminal blocks, and mounting structure.
2Reliability
If a printed circuit board with multiple contact fields is used, then electrical connections can be made, but the ease of manufacture decreases due to increased production complexity
Solution Approach 1:
The patent merges the functions of the printed circuit board, terminal blocks, wire guides, and mounting structure into a single molded plastic part. This integration eliminates multiple assembly steps and reduces the number of separate components that need to be manufactured and assembled, thereby significantly improving ease of manufacture while maintaining reliable electrical connections.
3Reliability
If conventional sensor manufacturing methods are used, then sensors can be produced, but productivity is low due to lack of automation and complex assembly steps
Solution Approach 1:
The molded plastic part is pre-formed with integrated guide channels and contact fields during the molding process. This preliminary action eliminates the need for subsequent assembly steps to create these features, allowing for direct assembly of the measuring resistor and connecting wires, thereby significantly improving manufacturing efficiency and enabling better automation.
4Ease of manufacture
If the measuring resistor is fully exposed for electrical connection, then connecting wires can be easily connected, but the measuring resistor is vulnerable to external influences
Solution Approach 1:
The molded plastic part provides localized protection: it completely encloses the measuring resistor to protect it from external influences, while simultaneously creating localized openings or contact fields that expose only the necessary electrical contact areas. This allows the measuring resistor to be protected wherever possible while maintaining ease of electrical connection where required.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method for manufacturing an electrical sensor (1), in particular a temperature sensor, in which a carrier element (2) made of plastic is equipped with a wireless measuring resistor (3), preferably in the form of an SMD component. According to the invention, the carrier element (2) equipped with the measuring resistor (3) is connected to a molded part (4) made of plastic, such that the measuring resistor (3) is partially covered by the molded part (4). Subsequently, the measuring resistor (3) is electrically connected to connecting wires (7, 8) via electrical connection surfaces (5, 6) that are at least partially exposed. The invention further relates to a molded part (4) for an electrical sensor (1) and to an electrical sensor (1) with such a molded part (4).