Sensor Cover with Protruding Bus Bars for Heating Access
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Solution Overview
Problem
Existing sensor assemblies for motor vehicles face challenges in accessing electrical contacts for heating features integrated in plastic layers, leading to precision issues, optical sink marks, and robustness problems due to thin conductor paths being easily damaged or pierced.
Innovation Solution
A sensor assembly with a heating feature where conductor paths are applied to a backing film and molded into the cover element, with bus bars connecting them to protrude and form electrical connecting elements, allowing for exposed electrical contact without being covered by the plastic layer, enhancing robustness and optical appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor paths are integrated in a plastic layer during injection molding, then the heating feature is protected and integrated, but the electrical contacts become inaccessible and require precise exposure
Solution Approach 1:
The bus bars are extracted from the plastic layer by forming them to protrude from the cover element's outer surface. This allows the electrical contacts to be accessible while the conductor paths remain integrated and protected within the plastic layer, resolving the contradiction between integration and accessibility.
Solution Approach 2:
Different regions of the heating feature have different properties: the conductor paths are embedded in the plastic layer for protection, while the bus bars protrude from the surface for electrical connection. This local differentiation allows simultaneous achievement of protection and accessibility.
2Illumination intensity
If conductor paths are made thin-layered to reduce visibility, then optical appearance improves, but robustness decreases and they become easily damaged
Solution Approach 1:
The conductor paths are designed with different thicknesses in different regions: thin in areas requiring optical transparency and thicker in areas requiring mechanical strength, particularly where bus bars connect. The plastic layer provides additional protection to thin conductor paths.
Solution Approach 2:
The plastic layer is applied beforehand to cover and protect the conductor paths, providing mechanical cushioning and protection against damage while maintaining optical transparency where required.
3Ease of operation
If electrical contact areas are exposed during injection molding, then accessibility improves, but manufacturing precision requirements increase
Solution Approach 1:
The bus bars are formed to protrude from the cover element before final assembly, and their positions are predetermined in the mold design. This preliminary positioning simplifies subsequent electrical connections and reduces the precision requirements during the injection molding process.
4Reliability
If cover element thickness is reduced in heating film areas, then integration improves, but optical quality deteriorates with sink marks
Solution Approach 1:
The cover element has varying thickness: thinner in areas where heating features are integrated and thicker in areas requiring high optical quality. The bus bar regions maintain sufficient thickness to prevent sink marks while allowing electrical connection access.
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 configuration improves the visual appearance and robustness of the sensor assembly by making electrical connections more accessible and reducing the risk of damage, while also simplifying the production process and increasing reliability.
Implementation Method 1
a heating feature comprising a plurality of conductor paths, which are applied to a backing film in particular by screen printing or wire laying
Data Source
AI summary
A vehicle sensor assembly having at least one sensor element emitting and/or detecting electromagnetic radiation in at least one measuring direction to determine a measuring signal, a cover element in front of the sensor element in the at least one measuring direction being an injection-molded plastic part having at least one layer transparent to the electromagnetic radiation, and a heating feature having a plurality of conductor paths applied to a backing film molded to the cover element, the backing film including the conductor paths thus forming an insert of the injection-molded cover element, the conductor paths being at least partially located on the side of the backing film facing the sensor element. The conductor paths are connected together by at least two bus bars that each at least partially form an electrical connecting element protruding from the cover element and being exposed for electrical contact with the electrical connecting elements.