Stamped Sensor Carrier with Flexible Conductor Foil
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Solution Overview
Problem
Existing sensor arrangements for motor vehicle control devices are complex and costly to manufacture due to the need for complicated and expensive injection molding tools and additional tools for punched grids, making them inefficient and expensive.
Innovation Solution
A sensor carrier and module utilizing a stamped sheet metal carrier plate with bent strip-shaped extensions for sensor positioning and a flexible conductor foil for electrical connection, which can be easily bent into position and manufactured without the need for complex tools, allowing for flexible angulation and protection against chips and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stamped grid with base body (sensor dome) is used for electrical connection, then electrical connection between sensor and control unit is achieved, but manufacturing complexity and cost increase due to required injection molding tools and punching/bending tools
Solution Approach 1:
The patent extracts the electrical connection function from the complex sensor dome structure (stamped grid + base body + injection molding) and implements it separately using a flexible conductor foil that is laminated or glued onto the carrier plate. This separates the mechanical support function (carrier plate) from the electrical connection function (conductor foil), eliminating the need for injection molding tools and punching/bending tools while maintaining reliable electrical connection.
2Ease of manufacture
If complex injection molding process is used for sensor dome, then sensor mechanical support and electrical connection are provided, but production cost increases due to expensive tooling requirements
Solution Approach 1:
The patent replaces the expensive, complex injection molded sensor dome with simpler, cheaper components: a stamped sheet metal carrier plate and a flexible conductor foil. These components can be manufactured using less expensive tools and processes, significantly reducing tooling costs while providing the necessary mechanical support and electrical connection functions.
3Adaptability or versatility
If stamped sheet metal carrier plate with bent extensions is used, then sensor positioning at difficult sensing positions is enabled, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses bent extensions (cantilevers) on the carrier plate that can be shaped into various angles and configurations to reach difficult sensing positions. The bending process allows the extensions to be formed into complex three-dimensional shapes that adapt to different sensor mounting locations, providing high positioning flexibility while using standard sheet metal bending processes.
Data Source
Figure 1~2
AI summary
The invention relates to a sensor carrier (1), in particular for use in an on-board control unit for a motor vehicle, comprising a carrier plate (2), which accommodates and positions at least one sensor (3) and a flexible conductor film (4) on the carrier plate (2) as an electrical connection between the sensor (3) on the carrier plate (2) and the control unit. A strip-shaped cantilever (5) leads away from the carrier plate (2) in such a way that the sensor (3), which is arranged at the end of the cantilever (5), is positioned at the intended sensing position thereof when the control unit is installed in the motor vehicle. The carrier plate (2) can also have more than one strip-shaped cantilever (5) and thus forms a sensor module (1).