Standardized Sensor Preform for Flexible Contact Integration
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Solution Overview
Problem
Current sensor manufacturing processes are not standardized, requiring specific processes for each sensor design and operating use, leading to inefficiencies and increased susceptibility to faults.
Innovation Solution
A method involving pre-injection molding around a sensor element with IC to create a standardized pre-molded part that can accommodate various sensor elements and electric contacts of different dimensions and positions, allowing for flexible adaptation to specific operating uses through an interference fit, followed by injection molding to produce the finished sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a specific special manufacturing process is used for each sensor, then the sensor can be optimized for its specific operating use, but the manufacturing process complexity increases and standardization is lost
Solution Approach 1:
The manufacturing process is divided into modular segments: a standardized base component is produced first, then specific sensor elements and electric contacts are added in subsequent steps. This allows the common standardized steps to be performed once, while specific customization steps are added only when needed, reducing overall process complexity while maintaining adaptability.
Solution Approach 2:
The standardized base component is produced in advance with pre-defined interfaces and mounting structures. This preliminary standardized production allows subsequent customization steps to be simpler and more efficient, as the foundation is already prepared and optimized for various sensor types without requiring complete re-manufacturing for each application.
2Manufacturing precision
If different manufacturing measures are used for different sensor designs, then each sensor can be optimized for its design requirements, but production efficiency decreases and costs increase
Solution Approach 1:
A universal standardized base component is designed that can accommodate multiple sensor types and configurations through standardized interfaces, mounting structures, and connection points. This single universal component replaces the need for multiple specialized manufacturing processes, maintaining design optimization while significantly improving production efficiency through standardization.
3Ease of manufacture
If electric contacts are injected at the same time into the pre-molded part, then the manufacturing process is simplified, but the adaptability to different contact types and positions is reduced
Solution Approach 1:
The manufacturing process separates the production of the standardized pre-molded part from the addition of electric contacts. The pre-molded part is produced first with standardized features, then electric contacts of different types, dimensions, and positions are added in subsequent customization steps. This segmentation maintains ease of manufacture for the base component while preserving full adaptability for contact selection.
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 enables standardized production of sensors for diverse applications, reducing production costs and errors by allowing for interchangeable electric contacts and components, while maintaining precise positioning and protection during the manufacturing and service life of the sensor.
Implementation Method 1
a pre-molded part (sub-module) which is realized such that, as a result of an interference fit, it is able to receive electric contacts for the sensor with different dimensions and/or in different positions
Implementation Method 2
insert the pre-molded part into an injection molding mold and injection mold around the pre-molded part to produce the finished sensor
Data Source
AI summary
The invention relates to a method for producing a sensor. In the method, a sensor element having an IC is pre-overmolded to produce a preform, wherein the preform is designed in such a way that the preform can accommodate electrical contacts for the sensor having various dimensions and/or in various positions by press fitting. The electrical contacts are pressed into holes/recesses of the preform, the connections of the IC of the sensor are connected to the electrical contacts, and the preform is inserted into an injecting mold and is overmolded to produce the finished sensor. In this way, sensors for different applications can be produced in a substantially standardized manner. The invention further relates to a sensor.