Vehicle Seat Occupancy Sensor Crimp Contact Segmentation
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Solution Overview
Problem
Existing seat occupancy detection modules using film pressure sensors face issues with loose connections during assembly and handling due to long electrical supply cables, which complicate the installation process and can lead to mechanical stress on connection points.
Innovation Solution
A module with crimp contacts that are inserted into receptacles on the connecting element, allowing for a plug-in connection that engages with a socket, providing a secure and frictional contact, and an optional latching mechanism to prevent detachment, along with a lamp holder for additional functionality, such as illuminating the footwell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long electrical supply cables are connected directly to the film pressure sensor, then the sensor can be connected to the control unit, but the cables can come loose at the connection point and impede handling during assembly
Solution Approach 1:
The electrical connection system is segmented into multiple parts: crimp contacts integrated with the film pressure sensor, a connecting element with receptacles on the carrier element, and separate plug-in connection. This segmentation allows the sensor to be handled without long cables attached during assembly, while ensuring reliable electrical connection is established after proper positioning.
Solution Approach 2:
The crimp contacts are pre-integrated with the film pressure sensor during manufacturing, and the connecting element with receptacles is pre-installed on the carrier element. This preliminary preparation eliminates the need for handling long cables during assembly operations, as the electrical connection is established through a simple plug-in action after positioning rather than during handling.
2Reliability
If the film pressure sensor is directly connected to the control unit with long cables, then electrical connection is established, but the cables mechanically stress the connection points and can come loose
Solution Approach 1:
The connection system is divided into rigid structural components (crimp contacts, connecting element, receptacles) that are integrated into the sensor assembly and carrier element. This segmentation creates short, rigid electrical pathways that eliminate the mechanical stress and loosening problems associated with long flexible cables.
Solution Approach 2:
The connecting element with receptacles acts as an intermediary component between the crimp contacts on the film pressure sensor and the control unit connection. This intermediary provides a stable, rigid connection point on the carrier element that eliminates direct stress on the sensor's connection points while maintaining reliable electrical connectivity.
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 simplifies the handling and assembly of the module by preventing loose connections and allowing for secure electrical connections post-installation, enhancing the module's usability and sensitivity through a compressible reaction layer and a dimensionally stable cover plate.
Implementation Method 1
The free end of the crimp contact can be inserted into a corresponding receptacle of the connecting element and can be contacted by a counter-contact in the region of this receptacle
Implementation Method 2
enhancing the module's usability and sensitivity through a compressible reaction layer
Implementation Method 3
along with a lamp holder for additional functionality, such as illuminating the footwell
Data Source
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Figure 5~6
AI summary
The invention relates to a module for seat occupancy detection of a vehicle seat, comprising a carrier element onto which a foil pressure sensor is placed, the foil pressure sensor comprising at least one sensor cell and at least two connecting conductors, each with a contact end, and a connecting element arranged on the carrier element, which receives the contact ends of the connecting conductors. A crimp contact is crimped onto each contact end of the connecting conductors, each of which can be inserted with its free end into a corresponding receptacle of the connecting element and can be contacted in the area of this receptacle by a mating contact.