EP2201578B1 - Flexible electrical connection - Google Patents

Description

State of the art

Out DE 10 2005 002 813 B4 a control module has become known, which is used in particular on a motor vehicle transmission. The control module according to the DE 10 2005 002 813 B4 comprises a first housing part, on which an electronic circuit part is arranged. The control module further comprises a second housing part and a carrier, on which a flexible conductor foil is arranged. The flexible conductor foil extends within a housing interior formed between the first housing part and the second housing part and is electrically connected to the circuit part and outside of the housing interior with electrical components fixed to the support. The second housing part is placed on the flexible conductor foil. The control module has a basically stack-shaped construction, in which the carrier is disposed with a first side resting on a provided with the circuit part inside of the first housing part. The circuit part is arranged in a recess of the carrier and the flexible conductor foil is arranged on the second side of the carrier facing away from the first housing part. Out GB 2 096 818 A is a flexible electrical connection has become known. According to the current state of the art sensors that are part of a control module or a sensor module, either firmly connected to the module, such as by means of a Warmverstemmung, or the sensors are electrically connected via a simple wiring with the corresponding module. The formation of a simple electrical wiring means that the sensors in the non-installed state and during assembly are usually free to move. In the case of simple cabling, damage to the cable may occur during handling of the sensors, during assembly or even during operation of the sensor arrangement, including sensor, sensor or control module and electrical conductor. There is also the risk of the electrical conductor running as a simple cable, twisted and the sensor is installed in a wrong mounting position. In addition, the mounting of such sensors relative to other solutions is relatively time consuming.

For permanently fixed sensors, new components and additional testing devices are required for each application. Furthermore, it should be noted as a disadvantage that the entire module is to be manufactured in a very high precision, since a tolerance compensation can be required by the stationary arrangement of the overall module. In addition, different sized packages are required.

Disclosure of the invention

According to the invention, an arrangement according to claim 1 is proposed, in which electrically conductive connections, which are formed, for example, as a cable, strand or flex foil or the like, are protected against mechanical damage during assembly and operation. This allows the use of the inventively proposed flexible electrical connection in particular sensors, plugs or actuators. When installing the inventively proposed electrical connection this can be deformed and assume an individual, the space requirements invoice bearing mounting position. Missing encapsulation or encapsulation enveloping the electrical conductor of a plastic material, seen in different lengths in the direction of the conductor extension, allow a targeted deformation of the flexible electrical connection, so that a frictionless, kink-free installation of the flexible electrical connection in the installation case and during assembly is guaranteed ,
Furthermore, it can be provided in an advantageous manner by the inventively proposed flexible electrical connection a way to realize with a flexible electrical connection different installation variants, without the use of more parts would be required. Compared to previously used in the prior art fixed connections between a sensor, plug or actuator and an associated sensor / control module, a simplified version of a tolerance compensation can be provided by the inventively proposed flexible electrical connection. moreover prevents the inventively proposed flexible electrical connection in improper handling, for example, when the control module, which is usually heavier than the sensor, is worn on the sensor that eg forces, in the above-mentioned case, the weight force acting on the electrically conductive connections and damage them so that a failure of the electrical conductor occurs during operation.

The predefined rigidity of the flexible electrical connection proposed according to the invention, be it used in individual cables, in strands or for sheathing individual sections of a flex foil against a simple cable connection known from the prior art, enables twist protection during handling and is therefore safer, what an assembly eg a sensor, plug or actuator counteracts in a wrong mounting position. Since in the flexible electrical connection of a sensor, plug or actuator to a control / sensor module, the mobility e.g. can be designed targeted against a simple wired sensor, such as by a different length or stiffness of individual, one or more electrical conductors enclosing Umspritzungsabschnitte, the positioning of the electrical connection during the assembly process can be specified and thus a faster and easier and considerably safer expiring assembly process get supported. In addition, by the flexible electrical connection proposed according to the invention, the packaging volume can be compared to a rigid embodiment, i. a fixed connection, e.g. between a sensor and a sensor module, can be significantly reduced, since the sensor can be used in a e.g. can be delivered to the housing of the sensor or control module folded position, which significantly reduces the volume to be packaged.

In a preferred embodiment, the flexible electrical connection is performed by at least one plastic extrusion around the electrical conductors, which may be formed, for example, as a cable, cable bundle, as a strand or as a flex foil. The inventively proposed flexible electrical connection can be formed, for example, as an encapsulation of the electrical conductor or in which individual Umspritzungsabschnitte in a thin hinge-like encapsulation, which allows deformation, and other portions of the encapsulation of a thicker, stronger and stiffer executed Kunststoffumspritzung be executed. It can also be formed individual cable sections of the cable bundle free from encapsulation, which in this case represent a kind of film hinge and have a deformation behavior or a stiffness, which is different from the deformation or stiffness behavior provided with an encapsulation cable or films or Litzenabschnitte. In an advantageous embodiment of the idea underlying the invention, sections of the extrusion coating, which are formed in a thin, hinge-like extrusion mold or do not have an encapsulation, and thicker, with a higher wall thickness and therefore more rigid encapsulation sections, alternate. The number of these alternately successive sections along the axial length of the electrical conductor, be it a cable, a cable bundle, a strand, a flex foil or the like, is chosen according to the respective application. The mechanical attachment of the electrical conductor by the proposed electrical flexible connection to a sensor module or to a control module can be done, for example, in the classical manner by means of a clip or even by way of heat staking, by screws, rivets or other non-positive or cohesive connection. Preferably, the flexible electrical connection is designed so that it runs without damage caused by adjacent components when mounted in a housing. A deflection of the electrical conductors preferably occurs due to the existing lower rigidity of the encapsulation where the at least one electrical line is surrounded by a hinge-like encapsulation element, which is made in a smaller wall thickness, or where an encapsulation of plastic material is missing and a free section the electrical conductor is left. Also, by specifying the axial length with respect to the electrical conductor, the rigidity or a specific deformation path or a targeted deformation of the surrounded by at least one encapsulation electrical conductor can be specified.

The inventively proposed flexible electrical connection of a sensor, or the like is preferably used on sensors in which at least for example, a sensor via at least one electrical conductor to be electrically connected to a control module or a sensor module. Training The electrical conductor itself can be designed as a single cable, as cable strands, as twisted cable strands, as a stranded wire or as a flex foil.

Brief description of the drawings

Figur 1

eine Sensorbaugruppe gemäß des Standes der Technik mit einer starren Verbindung zwischen Sensorelement und Sensormodul,

Figur 2

eine Ausführungsform der erfindungsgemäß vorgeschlagenen elektrischen Anbindung mit in einer geknickten Lage befindlicher, flexibel ausgebildeter Sensoranordnung,

Figur 3

die in Figur 2 dargestellte flexible elektrische Anbindung in gestreckter Lage in einer Einbauposition,

Figur 4

die Seitenansicht der erfindungsgemäß vorgeschlagenen flexiblen elektrischen Kontaktierung in geknickter Lage und

Figur 5

die Seitenansicht der erfindungsgemäß vorgeschlagenen elektrischen Anbindung in einer weiteren Einbaulage.

With reference to the drawing, the invention will be described below in more detail. It shows:

FIG. 1

a sensor assembly according to the prior art with a rigid connection between sensor element and sensor module,

FIG. 2

an embodiment of the inventively proposed electrical connection with located in a bent position, flexibly formed sensor arrangement,

FIG. 3

in the FIG. 2 illustrated flexible electrical connection in the extended position in an installed position,

FIG. 4

the side view of the inventively proposed flexible electrical contact in a bent position and

FIG. 5

the side view of the inventively proposed electrical connection in a further installation position.

embodiments

The representation according to FIG. 1 is to be taken from a known from the prior art rigid electrical connection.

As FIG. 1 shows, a sensor 10 is electrically connected to a sensor module 12 via an electrical conductor 14. In the in FIG. 1 illustrated arrangement, the electrical conductor 14 is designed as a rigid electrical connection 28. The sensor 10 is housed in a sensor housing 22. Above the rigid electrical connection 28 is a movable Component 18, which is shown in the illustration FIG. 1 at a first distance 24 from the periphery of a stationary component 20 is located. The sensor module 12 is located, for example, in a vehicle transmission. The rigid electrical connection 28 extends below the movable component 18 and above the stationary component 20 and is connected via a rigid coupling 30 to a housing 16 of the sensor module 12.

The representation according to FIG. 2 is a perspective view of an inventive proposed electrical connection.

As FIG. 2 can be removed, the housing 16 of the sensor module 12 and the recorded in the sensor housing 22 sensor 10 via electrical conductors 14 are electrically connected to each other. As shown in FIG. 2 For example, the electrical conductor 14 may be formed as a flex foil, as a strand or as a cable or cable bundle.

As the perspective rendering according to FIG. 2 can be seen, the electrical conductor 14 has a first portion 32, and on the other hand, a subsequent to this second portion 34 with an encapsulation. The first portions 32 and the second portions 34 follow each other alternately with respect to the axial length of the electrical conductor 14. The first sections 32 can be executed both without encapsulation, as well as be provided with a thin, film-hinge-like encapsulation, which is thinner compared to the thickness of the encapsulation of the second portions 34. The term film-hinge-like hereinafter is to be understood as meaning a thickness which has a film hinge made of plastic material.

The first portions 32 differ from a second portion 34 following therefrom, either by the lack of overmolding or by the thickness of the plastic material from which the electrical conductor 14, be it a cable, a cable bundle, a flex foil or a strand, at least partially is surrounded, and which affects the flexural rigidity of the electrical conductor 14.

In FIG. 2 shown kinked layer 42, the electrical conductor 14 is bent in the overmold portion 32.

As shown in the illustration FIG. 2 Furthermore, connections of the electrical conductors 14 to the sensor housing 22 of the sensor 10 on the one hand and to the housing 16 of the sensor module 12 on the other hand are not shown here. The representation according to FIG. 2 can be taken that a second section 34 follows on the electrical conductor 14 to a first section 32, which takes on a film hinge function, in turn, followed by a first section 32 and so on. Advantageously, the wall thickness of the extrusion coating of the second section 34 is selected so that the bend 48 adjusts in the region of the first section 32 due to the higher rigidity. By the execution of the encapsulation at the second portions 34 and the second portions 32 without encapsulation or in a thin, film hinge-like encapsulation in terms of their axial length and in terms of the thickness in which the encapsulation is made with respect to the at least one electrical conductor 14 can a specific deformation are given, so that - as in FIG. 2 indicated - the electrical conductor 14 assumes its strongest deformation at the point where this is desired.

The representation according to FIG. 3 is to be taken from the invention proposed flexible electrical connection in another mounting position.

As FIG. 3 can be removed, it is at least one electrical conductor 14, be it a single cable, a cable bundle, whether strands, flex foils, positioned in an indicated by reference numeral 44 mounting position. Compared to the representation according to FIG. 2 is the housing 22 of the sensor 10 in a different position to the housing 16 of the sensor module 12 further away. How out FIG. 3 shows, the at least one electrical conductor 14 assumes the stretched layer 44, which is indicated for example by a second bend 56 in this mounting position 44. In the installation position 44 as shown in FIG FIG. 3 is the at least one electrical conductor 14 in comparison to the bent layer 42 according to FIG. 2 not so strongly bent within the first section 32, but in the mounting position 44, as in FIG. 3 shown, only at a smaller angle.

From a comparison of the Figures 2 and 3 shows that the flexible electrical connection 28 deforms in the mounting positions shown there to varying degrees is bent in the present case, and the sensor 10 with the sensor module 12 in the in FIG. 2 and 3 connecting cases electrically connected to each other. Due to the alternating sequence of first sections 32 without encapsulation or with a thin, film hinge-like encapsulation and second sections 34 with encapsulation, the at least one electrical conductor 14 in different mounting positions 42, 44 a specific deformation can be specified. By appropriate design of the axial length of the at least one electrical conductor 14 and positioning of the first portions 32 and the second portions 34 with encapsulation of the contact and a resulting damage to the at least one electrical conductor 14 with other components, such as a movable member 18th (see FIG. 4 ), be avoided.

From the illustration according to FIG. 4 the in goes FIG. 2 shown kinked position of the flexible electrical connection out.

As FIG. 4 shows, the at least one electrical conductor 14 is in the direction indicated by reference numeral 42 kinked mounting position. Below the sensor housing 22, the at least one electrical conductor 14 is connected to the sensor housing 22 at a coupling 46. The coupling 46 may, for example, also be embodied as an encapsulation made of plastic material in order to avoid an excessive buckling of the electrical conductor or conductors 14 immediately below the sensor housing 22 of the sensor 10. Below the coupling 46, a first portion 32, which is formed in a first thickness 36 extends. The thickness 36 of the first section 32 is given either by the thickness of the overmold-free executed first portion 32 or by the thickness of the provided with a thin, film hinge-like encapsulation first portion 32. The first portion 32 may extend in different lengths along the at least one electrical conductor 14, depending on the desired degree of deformation of the flexible electrical connection 28 and depending on the available installation space. By selecting the length of the first portions 32 and the length of the second portions 34 with encapsulation, the deformation or deformation capacity of the electrical conductor 14 can be defined defined, so that this - can be placed in a specific position - for example, during assembly, in For example, the sensor housing 22 with sensor 10 received therein also remains permanently.

Below the first section 32 on the rigid or rotatable coupling 46 on the sensor housing 22 extends, enclosing the at least one electrical conductor 14, a second section 34 with encapsulation. As a comparison of the thickness 36 of the first portion 32 and the thickness 38 of the second portion 34 according to FIG. 4 is apparent, the second portion 34 is formed with a first encapsulation in a second thickness 38, which exceeds the thickness 36 of the first portion 32. Consequently, due to the greater material thickness in the region of the second section 34 with encapsulation, designated by reference numeral 38, a deformation of the flexible electrical connection 28 is made more difficult due to the greater rigidity. In the following on the second section 45 with encapsulation, another film hinge-like encapsulated or extrusion-free running executed first section 32, however, prevails - as in FIG. 2 already indicated - the first bend 48 before. As a result, the adjoining second section 34 with encapsulation lies almost in a horizontal position and extends to a coupling 54, which is rotatable in this embodiment, on the outside of the housing 16 of the sensor module 12 FIG. 4 Furthermore, it can be seen that between the arranged in a first mounting position component 18 and a periphery 60 of the stationary member 20, the first distance 24, which is already in FIG. 1 is indicated. The FIG. 4 FIG. 3 shows a deformation of the at least one electrical conductor 14 defined in an alternating sequence on the basis of the first sections 32 and the second sections 34 with encapsulation in the region in which the first sections 32 formed in the smaller thickness 36 are located. Depending on the length of the first sections 32 and / or the second sections 34 with encapsulation-seen in the axial direction of the at least one electrical conductor 14 -a predetermined deflection path of the at least one electrical conductor 14 can be predetermined. This takes, for example, the in FIG. 4 shown first contact position (kinked position) 42 and lies without contact between the periphery 60 of the stationary member 20 and the lower side of the component 18. While the coupling 46 of the at least one electrical conductor 14 to the sensor housing 22 of the at least one sensor 10 to look approximately rigid is, the other coupling, ie the rotatable coupling 54, designed to be rotatable to the housing 16 of the sensor module 12, so that the at least one electrical conductor 14 is easier to regulate during its assembly. The coupling 54 may alternatively be designed as a rigid coupling. The component 18 may be both a stationary component, as well as a component, which in vertical direction 40 within a housing, for example, relative to the flexible electrical connection 28 is movable.

The representation according to FIG. 5 is another installation position of the flexible electrical connection refer.

As FIG. 5 shows, the inventively proposed flexible electrical connection 28 connects the at least one embedded in the sensor housing 22 sensor 10 with the housing 16 of the sensor module 12. As from FIG. 5 As can be seen, take the sensor housing 22 and the component 18 in the illustration according to FIG. 5 a vertically displaced installation position, resulting in a different mounting position 44, in which the inventively proposed electrical connection 28 extends. As FIG. 5 shows, extends below the rigid coupling 46 of the at least one electrical conductor 14 on the underside of the housing 22, a first portion 32 in a first axial length 50. Wie FIG. 5 Furthermore, the thickness of the first, overmoulded or in a small thickness 36 molded portion 32 is less than the thickness 38, in which the second portion 34 with encapsulation, which is applied to the first portion 32 in the axial direction of the at least one electrical conductor 14 connects, is executed. Because of this, the first sections 32 have a higher deformation capacity, ie can be deflected more easily in comparison with the second sections 34 with encapsulation. Due to the thicknesses 36, 38 of the first sections 32 or of the second sections 34 with encapsulation and the lengths 50, 52 of the sections 32, 34, a defined deformation can be impressed on the at least one electrical conductor 14. This then takes, such as the FIG. 5 represents an installation position 44 between the rigid coupling 46 on the sensor housing 22 and the rotatable - alternatively rigidly executable - coupling 54 on the housing 16 of the sensor module 12 a.

In the representations according to the FIGS. 2 to 5 the first sections 32 and the second sections 34 are provided with encapsulation along the axial length of the at least one electrical conductor 14 in an alternating sequence. Alternatively to the formation of the first sections 32 or the second sections 34 with encapsulation in different lengths 50, 52 and different thicknesses 36, 38, a defined deformation of the at least one electrical conductor 14 by the flexible electrical connection 28 also be lent that on the individual longitudinal sides of the at least one electrical conductor 14, a portion of plastic material, for example, one or more layers can be applied and on the one or more multilayer plastic section opposite side completely missing. As a result, depending on the application, a defined deformability can be impressed on the at least one electrical conductor 14, which can considerably facilitate the assembly of the at least eg a sensor 10 or of the sensor housing 22 on a vehicle transmission, for example, and thus drastically reduce assembly time.

With the inventively proposed, formed on at least one electrical conductor 14 flexible electrical connection 28 can be made by applying first portions 32 and second portions 34 with encapsulation in an alternating sequence, various applications with one and the same flexible electrical connection 28. As a result, an unnecessary variety of parts can be avoided, which contributes to a significant cost reduction in mass production.

Claims (5)

1. Arrangement having a sensor (10), an electric conductor (14), a housing (16) of a sensor module or control module (12), a movable component (18) and a stationary component (20), comprising a flexible electrical connection (28) of the sensor (10) to the housing (16) of the sensor module or control module (12) by using at least one electric conductor (14) extending in an axial length between the movable component (18) and the stationary component (20), wherein the at least one electric conductor (14) has first sections (32) which are free of encapsulation or are encapsulated with a film-hinge-like thickness, and second sections (34) with encapsulation, wherein the first sections (32) and the second sections (34) extend in each case over a predefined length in relation to the axial length of the electric conductor (14) and follow each other in an alternating manner over the axial length of the electric conductor, and the first sections (32) have a thickness (36) which is lower than the thickness (38) of the second sections (34) with encapsulation, and wherein the first and second sections have a deformability that differs from each other, wherein a first section (32) of the at least one electric conductor (14) is fixed to a sensor housing (22) of the sensor (10) via a rigid coupling (46), and a second section (34) is coupled to the housing (16) of the sensor module and control module (12) via a movable coupling (54), which is rotatably designed, and wherein a second section (32) provided with the rotatably designed coupling (54) is arranged between the movable component (18) and the circumference of the stationary component (20), and the first sections (32) and the second sections (34) define a predefined deflection travel of the at least one electric conductor (14) in such a way that, in a bent installation position (42), a bend (48) of the electric conductor (14) of 90° or more can be set within a first section (32), by which means contact between the electric conductor (14) and the stationary component (20) and the movable component (18) in the bent installation position (42) is avoided.
2. Arrangement according to Claim 1, characterized in that the second sections (34) with encapsulation at least partly enclose the at least one electric conductor (14).
3. Arrangement according to Claim 1, characterized in that the at least one electric conductor (14) is embodied as a cable, cable bundle, flex, flexible film or leadframe.
4. Arrangement according to one or more of the preceding claims, characterized in that the at least one electric conductor (14) permanently maintains deformations performed on the latter during the mounting and installation positions (42, 44) impressed on the said conductor.
5. Arrangement according to Claim 1, characterized in that it can be set onto the housing (16) of the sensor module (12) in a parked position during transport.

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