Sensor Arrangement With Peripheral Collars For Short Circuit Protection
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Solution Overview
Problem
Existing sensor arrangements in the automotive industry face high production costs and risks of electrostatic discharge and short circuits, particularly in harsh environments like transmission and engine compartments.
Innovation Solution
A single-stage injection molding process is used to encase contact elements with a plastic body, incorporating peripheral collars that increase the distance between exposed fixing positions, preventing electrical discharges and short circuits by forming an integral part of the plastic body during overmolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-stage injection molding process is used to encase contact elements, then protection against electrostatic discharge and short circuits is improved, but production costs and process complexity increase
Solution Approach 1:
The patent combines the encasement of contact elements and the formation of protective collars into a single injection molding process. The plastic body is molded in one stage while simultaneously forming collars at the fixing positions of contact elements, eliminating the need for a separate second molding stage. This merging of operations reduces process complexity while maintaining the protective function against electrostatic discharge and short circuits.
Solution Approach 2:
The collars are formed during the initial injection molding process before the contact elements are fully assembled. By pre-forming the collars as integral parts of the plastic body during the first molding stage, the structure is prepared in advance to provide protection against electrostatic discharge and short circuits, eliminating the need for subsequent protective measures.
2Reliability
If collars are added to increase distance between fixing positions, then protection against short circuits is improved, but manufacturing complexity increases
Solution Approach 1:
The collars are integrated into the plastic body as a single molded part. The injection molding process simultaneously creates both the main plastic body and the collars at the contact element fixing positions, forming them as one unified component. This eliminates the need for separate manufacturing steps for the collars, reducing manufacturing complexity while achieving the required distance for short circuit protection.
Solution Approach 2:
The plastic body and collars are formed as an integrated composite structure through injection molding. The single-stage process creates a unified plastic component that combines the structural function of the body with the protective function of the collars, simplifying manufacturing while maintaining effectiveness against short circuits.
3Ease of manufacture
If a single-stage injection molding process is used, then production costs are reduced, but protection against electrostatic discharge may be insufficient
Solution Approach 1:
The single-stage injection molding process combines multiple functions into one operation: encasing the contact elements, forming the plastic body, and creating the protective collars at the fixing positions. This consolidation reduces production costs while the simultaneously formed collars provide the necessary protection against electrostatic discharge and short circuits.
Solution Approach 2:
The injection molding process parameters are optimized to simultaneously achieve proper encasement of contact elements and formation of collars with sufficient height and spacing. By adjusting molding parameters such as injection pressure, temperature, and mold design, the single-stage process achieves both cost efficiency and adequate protection against electrostatic discharge.
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
This approach reduces production costs while ensuring effective protection against electrostatic discharge and short circuits, enhancing the reliability of sensor arrangements in demanding automotive environments.
Implementation Method 1
The contact element is encased in a plastic body in a single-stage injection molding process
Data Source
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AI summary
A sensor arrangement (1) comprises a sensor element (3). A contact element (6) is in electric contact with the sensor element (3) on the one hand and with contact pins (4) on the other hand. The contact element (6) is encapsulated by a plastic body (5). The contact element (6) is fixed to fixing positions (7) during encapsulation. The contact element (6) is exposed at said fixing positions, each of which comprises a peripheral collar (8) made of a plastic material at the exposed points of the contact element (6). Thus, a sensor arrangement is provided, the production expenditure of which is reduced compared to the prior art while maintaining the same degree of protection against undesired electrostatic charges or against the formation of an undesired short circuit.