Sensor Holder Integrating Spacing and Separator Elements
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Solution Overview
Problem
Existing sensor arrangements face challenges in accurately positioning and electrically connecting connector elements and plug contacts due to manufacturing tolerances and the need for precise alignment, which can lead to electrical shorts and require additional sealing measures.
Innovation Solution
A sensor arrangement featuring a holder component with integrated spacing and separator elements allows for the flexible positioning and electrical connection of conductor ribbons, which adapt to offsets between connector elements and plug contacts, ensuring accurate alignment and preventing electrical shorts, while a sealing compound encloses the components for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If connector elements and plug contacts are positioned with high precision to prevent electrical shorts, then manufacturing precision is improved, but device complexity increases due to additional positioning aids and alignment mechanisms
Solution Approach 1:
The holder component integrates multiple functions: it provides mechanical support for connector elements and plug contacts, incorporates spacing elements to maintain precise distances, includes separator elements to prevent electrical shorts, and offers positioning aids all within a single unified structure. This merging eliminates the need for separate positioning aids and alignment mechanisms, achieving high positioning accuracy without increasing device complexity.
Solution Approach 2:
Spacing elements and separator elements act as intermediaries between connector elements and plug contacts. The spacing elements mediate the distance requirements to ensure proper alignment, while separator elements mediate electrical isolation to prevent shorts. These intermediary components simplify the overall positioning task by providing built-in reference features and isolation barriers.
2Reliability
If additional sealing measures are implemented to protect against electrical shorts, then reliability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The separator elements are integrated directly into the holder component structure, combining the electrical isolation function with the mechanical support structure. This eliminates the need for separate sealing measures while maintaining reliable electrical isolation between connector elements and plug contacts, thereby improving reliability without increasing device complexity or manufacturing steps.
3Manufacturing precision
If rigid positioning structures are used to ensure precise alignment, then manufacturing precision is improved, but adaptability to different plug variants decreases
Solution Approach 1:
The holder component incorporates flexible spacing elements and separator elements that can adapt their position within defined tolerances. This dynamic capability allows the rigid overall structure to maintain precise alignment while accommodating variations in plug contact positions across different plug variants, thereby achieving both manufacturing precision and adaptability.
Solution Approach 2:
The holder component is designed as a universal mounting structure that can accommodate multiple plug variants. The integrated spacing and separator elements provide standardized positioning references that work across different connector types, enabling a single holder design to maintain precise alignment for various plug configurations without requiring variant-specific modifications.
4Ease of manufacture
If multiple separate components are used for holder, spacing elements, and separator elements, then ease of manufacture is improved, but assembly time and productivity are reduced
Solution Approach 1:
The holder component is manufactured as a single integrated piece that includes built-in spacing elements and separator elements. This merging reduces the number of separate components from three (holder, spacing elements, separator elements) to one (integrated holder), thereby eliminating multiple assembly steps and significantly improving assembly speed and productivity while maintaining ease of manufacture through standardized production processes.
Data Source
AI summary
A sensor arrangement has a support component, a sensor element with at least two terminals, at least two plug contacts and at least two connection elements for electrically connecting the connection elements to the control contacts. The support component receives the sensor element with at least two terminals and the at least two plug contacts. Connection elements are positioned and spaced apart from one another in the support component by means of spacer elements and separator elements. The disclosure also relates to a corresponding production method.