Spring-Element Sensor Electrical Contact for Stress Decoupling
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Solution Overview
Problem
Existing peripheral sensor systems for pressure measurement face challenges in achieving uniform, robust, and cost-effective designs that can be easily tested and connected using flexible and variable connector systems, while maintaining a hermetic seal and mechanical stress decoupling.
Innovation Solution
A sensor system with a sensor element housed in a sealed unit, utilizing spring elements for electrical contacting with a plug connector, allowing for modular and stress-decoupled connections without welding, soldering, or gluing, and incorporating seals to maintain hermeticity and protect against external damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical contacting methods (welding, soldering, gluing) are used to connect plug connectors to sensor elements, then reliable electrical connection is achieved, but manufacturing complexity and cost increase, and mechanical stress decoupling is compromised
Solution Approach 1:
The patent replaces traditional mechanical electrical contacting methods (welding, soldering, gluing) with a spring element-based mechanical contact system. The spring element (1b) provides electrical contact through elastic deformation, eliminating the need for thermal or adhesive bonding processes. This substitution maintains electrical connection reliability while significantly simplifying the manufacturing process and enabling mechanical stress decoupling between the sensor cell and plug connector.
2Productivity
If sensor elements are tested and balanced early in production, then manufacturing efficiency and cost-effectiveness improve, but the sensor system requires modular design for flexible interfacing
Solution Approach 1:
The patent divides the sensor system into distinct modular components: a sensor cell (1) containing the sensor element (7) and housing (1a), and a separate plug connector (2). This segmentation allows the sensor cell to be fully tested and balanced during manufacturing while the plug connector can be independently configured for different applications. The modular design with standardized interfaces enables flexible interfacing without compromising production efficiency.
3Reliability
If hermetic sealing is implemented to protect sensor elements from external conditions, then sensor robustness improves, but connection flexibility and variable interfacing become more difficult
Solution Approach 1:
The patent extracts the electrical connection function from the hermetically sealed sensor cell by providing dedicated electrical contact elements (6b) that extend through the housing. This allows the sensor element to remain protected within the sealed housing while the external plug connector can be flexibly connected to different systems. The separation of sealing function and connection function maintains both robustness and flexibility.
4Stability of the object's composition
If spring elements are used for electrical contacting between plug connector and sensor element, then mechanical stress decoupling is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes the elastic properties of the spring element (1b) to compensate for manufacturing tolerances and misalignments. The spring's ability to deform elastically allows it to accommodate variations in contact element positions while maintaining reliable electrical connection. This parameter change from rigid to elastic connection reduces the stringency of manufacturing precision requirements while achieving mechanical stress decoupling.
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
The solution enables a robust, compact, and modular sensor system that can be tested early in production, ensuring reliable electrical and pressure connections, reducing manufacturing costs, and allowing flexible interfacing with various media and connectors, while maintaining hermeticity and mechanical stability.
Implementation Method 1
at least one spring element (1b), which is coupled for electrical contacting between the at least one second electrical contact element (2a) and the at least one first electrical contact element (6b)
Data Source
AI summary
A sensor system having a sensor element, a housing in which sensor element is situated and which seals the sensor element from the outside world, at least one first electrical contact element which is electrically coupled with the sensor element; a plug connector, which has at least one second electrical contact element, and at least one spring element which is coupled between the at least one second electrical contact element and the at least one first electrical contact element for electrical contacting, so that the sensor element is electrically connected to the second electrical contact element of the plug connector.