Motor Vehicle Sensor 3-Point Contact System
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Solution Overview
Problem
Existing sensor devices for motor vehicles, particularly pressure sensors, face complexity in manufacturing and high production costs due to intricate designs required for reliable electrical contacting, which can be prone to assembly errors and moisture ingress.
Innovation Solution
A sensor device with a 3-point contact system between the sensor element and the housing, utilizing punctiform abutment contacts and contact areas, along with a snap-in connection and elastic intermediate elements for assembly, ensures reliable and cost-effective electrical contacting while maintaining environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic or resilient plug connections are used to achieve reliable electrical contacting, then electrical contact reliability is improved, but device complexity increases due to curved contact contacts and required free space
Solution Approach 1:
The sensor element's support structure is segmented into discrete punctiform abutment contacts (first, second, and third abutment contacts) distributed at specific positions. This segmentation allows each contact point to independently provide support and electrical connection, simplifying the overall plug connection design while maintaining reliability without requiring complex elastic mechanisms
Solution Approach 2:
The invention uses simplified planar contact surfaces and fixed contact contacts that replicate the essential function of complex elastic plug connections. By copying the contact function in a simplified manner using flat contact surfaces and stationary contact contacts, the design achieves reliable electrical contacting without the curvature and mobility requirements of traditional elastic plug connections
2Reliability
If complex plug connections with curved contact contacts are used, then electrical contact reliability is improved, but manufacturing cost increases
Solution Approach 1:
The sensor element incorporates simple, planar contact surfaces and fixed contact contacts that can be manufactured using cost-effective processes. These simplified contact components replace expensive elastic plug connections with curved geometries, achieving reliable electrical contact through a more economical design that uses flat surfaces and stationary contacts
Solution Approach 2:
The invention changes the geometric parameters of the contact surfaces from curved (in elastic plug connections) to planar (flat surfaces). This parameter change simplifies manufacturing while maintaining contact reliability, as the punctiform abutment contacts on flat surfaces provide sufficient electrical connection without requiring the complex curvature and elasticity of traditional plug connections
3Reliability
If the sensor element is pressed down by a housing cover, then electrical contacting is improved, but assembly complexity increases
Solution Approach 1:
The housing cover combines multiple functions into a single component: it provides mechanical support, applies pressing force to ensure contact between the sensor element and abutment contacts, and seals the housing. This merging of functions simplifies the overall housing structure compared to designs requiring separate components for each function, reducing assembly complexity while maintaining reliable electrical contacting
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 3-point contact system provides defined electrical contacting, simplifies assembly, reduces production costs, and ensures secure and sealed operation, minimizing assembly errors and environmental hazards.
Implementation Method 1
An embodiment in which an elastic intermediate element is arranged between the housing cover and the sensor element is particularly preferred. This allows component tolerances to be compensated for and a secure electrical contact to be established.
Data Source
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AI summary
The invention relates to a sensor device (10), in particular for use in a motor vehicle, having a housing (11) for accommodating a sensor element (1), wherein the sensor element (1) has electrical contact areas (2, 3) which are connected to electrical plug connections (18, 19) arranged in the housing (11) in an electrically conductive manner in the region of contacts (23, 24) of the plug connections (18, 19), wherein a force is applied to the sensor element (1) for the purpose of making electrical contact with a housing element in the direction of the plug connections (18, 19). The invention provides for the electrical plug connections (18, 19) to be arranged in a stationary manner in the housing (11) in the region of the contacts (23, 24) with the electrical contact areas (2, 3) of the sensor element (1), and for a support to be formed between the sensor element (1) and the housing (11) in such a manner that the sensor element (1) has three-point contact in the housing (11).