WO2023248113A1

WO2023248113A1 - Protective cover for sensors relating to automotive engineering, and production method for a protective cover

Info

Publication number: WO2023248113A1
Application number: PCT/IB2023/056353
Authority: WO
Inventors: Manfred Gruber
Original assignee: Att Advanced Thermal Technologies Gmbh
Priority date: 2022-06-21
Filing date: 2023-06-20
Publication date: 2023-12-28
Also published as: AT526302A1

Abstract

The invention relates to a protective cover for sensors relating to automotive engineering, which protective cover is designed as a moulded part having heating elements (1) injection moulded from a plastic (11), and connection points (3) for the heating elements (1) for connecting a power supply. According to the invention, a plug connector is provided, which comprises a contacting element and a connection sleeve (5), which is integrally moulded on the moulded part, wherein the contacting element is formed by a printed circuit board (6) crossed by electrical contacts (8), which are connected, on a side of the printed circuit board (6) facing the connection points (3), to the connection points (3) by means of an electrically conductive adhesive (10) and are electrically contacted, on a side of the printed circuit board (6) facing away from the connection points (3), to contact pins (4), which project from the printed circuit board (6) and are framed by the connection sleeve (5). The invention also relates to a method for producing a protective cover and to the use of the protective cover.

Description

Protective cover for sensors in vehicle technology and

Manufacturing process for a protective cover

The invention relates to a protective cover for sensors in vehicle technology, which is designed as a molded part with heating elements injection-molded from a plastic and connection points for the heating elements for connecting a power supply, according to the preamble of claim 1 and a manufacturing method for a protective cover according to claim 18.

In vehicle technology, sensors such as cameras, radar and lidar sensors are used with protective covers that can be heated using heating elements. For this purpose, the protective covers are designed as molded parts in which heating elements are embedded. The heating elements ensure that certain temperature ranges are maintained for the sensors to function properly.

Typically, during the production of protective covers, heating elements are inserted into an injection molding tool and overmolded with plastic. back-injected. An area around the connection points of the electrodes is kept free of material in order to provide soldering points for connecting a power supply. When installing such a heatable molded part, the connection points can be connected to the cables of a power supply via soldered connections.

The installation of heatable protective covers of the known type is therefore associated with assembly effort, and the materials used for the electrodes and connection points are sometimes difficult to solder, such as silver-based pastes for silver tracks, which are also referred to as silver varnish. The poor solderability of silver varnishes sometimes impairs contacting or makes it necessary to avoid using silver varnishes.

DE 10 2019 106 865 Al discloses a method for producing a plastic part from a plastic film or plate with at least one part in the plastic arranged heating wire. In order to avoid a hole in the plastic part intended for contacting the at least one heating wire, the at least one heating wire can be electrically contacted via at least one contact socket or similar electrical connecting element arranged on a flat side of the plastic part. For this purpose, the at least one heating wire arranged in the plastic part is stripped of paint or the like in a contacting area before the at least one heating wire in the exposed contacting area is electrically contacted with the electrical connecting element in a subsequent method step.

The disadvantage of the known solution is that the electrical connection means must first be applied to the plastic plate or film and then the at least one heating wire with its at least one exposed or yet to be exposed contact area must be placed on the electrical connection means in order to then be soldered .

US 2021/0037610A1 discloses a body component with sensors in vehicle technology, which is designed as a molded part with multiple heating elements encapsulated in plastic and connection points for the multiple heating elements for connecting a power supply.

The disadvantage of the known solution is that the molded part consists of two plastic components. The first component comprises a carrier and contact pins as well as heating elements, and the second component comprises a connection sleeve, with the two plastic components being subsequently connected to one another.

An object of the invention is to avoid at least one of the disadvantages of the stand. In particular, the aim of the invention is to provide plastic molded parts that are easier to assemble and enable better contact.

A protective cover according to the invention for sensors in vehicle technology is a molded part with several heating elements injection-molded from a plastic and connection points for the several heating elements for connecting one Power supply executed. At least one plug connector is provided, which comprises a contacting element and a connection sleeve formed on the molded part, the contacting element being formed by at least one carrier element, the at least one carrier element being crossed by electrical contacts.

The plastic molded part therefore has a plug connector with a contacting element and a connecting sleeve into which a corresponding or Complementarily shaped plug can be easily inserted for connecting a power supply. The production of a soldered connection can therefore be omitted when installing the plastic molded parts, which simplifies the assembly effort of the protective covers according to the invention. The connection sleeve is molded onto the plastic molded part and is manufactured at the same time as the molded part in the injection molding process. The molded part can be produced by injection molding using overmolding, back-injection, injection molding, or other injection molding techniques. Other processes in which the components are embedded in plastic include. The electrical contacts run transversely through the at least one carrier element, so that they can be contacted at least on two sides and form an electrical connection through the at least one carrier element, for example to create a reliable electrical connection for the heating elements or for sensor data through the at least one carrier element fen.

The at least one carrier element is preferably cuboid and can have structured conductive surfaces on the top and bottom, which are separated by at least one insulation layer, for example a plastic, and only provide electrically conductive connections at defined locations of the at least one carrier element Form electrical contacts between the top and bottom. For example, the top is a side facing away from the connection points and the bottom is a side facing the connection points. The at least one carrier element is designed to be compact and can be easily further processed. In addition, the at least one carrier element is suitable for electrical Contacts to be equipped and to have dimensional stability when producing the protective cover in an injection molding process.

In particular, the at least one carrier element is designed as a circuit board, so that the contacting element is formed by at least one circuit board, with the at least one circuit board being crossed by electrical contacts. The board is conventionally made from FR4 or as a flexible board made from polyimide or PET. Alternatively, other carrier elements made of PEN, PC, PET or polyimide or ceramic substrates are suitable.

The several heating elements of the molded parts are manufactured, for example, as flat-shaped heating elements which are mounted on an electrically insulating carrier film, for example made of a polycarbonate or polyethylene or PET is applied as conductive tracks, in particular metal tracks, such as silver tracks, which, for example, run in a meandering or circular shape between two connection points. The silver tracks can be covered with an electrically insulating protective lacquer layer. A power supply can be connected to the connection points so that current flows through the silver strips and thus heats up.

In particular, the silver webs are designed as silver-based pastes, which are also referred to as silver lacquer and are applied to the carrier film in the desired arrangement in viscous form at room temperature by means of screen printing and thermally hardened, which enables cost-effective production. Since there is no need to solder the contacting elements, it is possible to use silver-based pastes in the protective cover according to the invention.

Alternatively, the metal tracks are designed as metal-based pastes, for example copper-based pastes, which are also referred to as metal varnish and are applied to the carrier film in the desired arrangement in viscous form at room temperature by means of screen printing and thermally hardened. Alternatively, the electrically conductive tracks are designed as conductive pastes, for example carbon-based pastes, which are also referred to as carbon varnish and are applied to the carrier film in the desired arrangement in viscous form at room temperature by means of screen printing and thermally hardened.

Alternatively or additionally, resistance elements and electrodes are arranged on a carrier film. The electrodes connect the resistance elements to connection points for connecting a power supply so that current can flow through the resistance elements. The resistance elements represent an electrical resistance in which electricity is converted into heat and thus form the desired heat source in the present application. These resistance elements can, for example, have a PTC effect (positive, preferably non-linear, temperature coefficient of ohmic resistance), whereby intrinsically stable heating elements can be generated that regulate at a certain temperature.

Preferably, the electrical contacts on a side of the at least one carrier element facing the connection points are connected to the connection points via an electrically conductive material. This means that the at least one carrier element is electrically contacted with the connection points and connected in a dimensionally stable and temperature-resistant manner.

In particular, the electrically conductive material is an electrically conductive adhesive f. The contacting element is prepared before being inserted into the injection molding tool by gluing the at least one carrier element to the connection points of the heating elements with the electrically conductive adhesive. The type of connection created between the at least one support element and the connection points has proven to be crucial, since high temperatures and high pressure briefly act on the injection-molded parts during the injection molding process. An adhesive connection has proven to be ideal because it has sufficient elasticity to primarily prevent thermally induced relative movements between the at least one support element and the connection points of the Heating elements should be balanced due to different expansions.

In particular, the at least one carrier element can consist of several structured metal elements, e.g. B. Stamped parts, which are spaced apart from one another and which are individually connected to the plurality of electrical contacts by means of the electrically conductive material.

Preferably, the electrical contacts are electrically contacted with contact pins on a side of the at least one carrier element facing away from the connection points. The plastic molded part therefore has a plug connector with contact pins and a connection sleeve into which a corresponding or Complementarily shaped plug for connecting a power supply can be easily plugged in, the contact pins not only providing the electrical contact, but also giving the plug connection mechanical stability.

The contact pins preferably protrude from the at least one carrier element. The contact pins are designed as projections which protrude from the at least one carrier element. This simplifies the assembly of the protective cover since the contact pins can be easily inserted into an opening of a complementary plug.

In particular, the contact pins are framed by the connection sleeve, so that they are protected by the connection sleeve at least from mechanical external impairments, such as impacts. Furthermore, the contact pins cannot be bent when installing the protective cover.

The plug connector preferably has at least two, in particular three, contact pins. In the case of two contact pins, the heating elements can be contacted with an external power supply and the protective cover can be heated. In the case of at least three contact pins, at least one sensor arranged in the protective cover can be contacted and its measurement data can be derived from the protective cover. There can also be more than three contact pins, so several in Sensors arranged on the protective cover can be contacted and therefore read out.

Preferably, the electrical contacts protrude beyond the at least one carrier element on the side facing the connection points, so that reliable contacting of the electrical contacts with the connection points is ensured. Particularly when producing the protective cover with the connector in an injection molding process, the components of the protective cover can shift due to the high pressures in the injection molding tool and its dimensional tolerances. Such shifts therefore do not influence the contacting of the electrical contacts with the connection points.

The electrical contacts are preferably framed in their peripheral areas by a protective layer. The protective layer preferably serves as a spacer between the at least one carrier element and the electrically conductive material or the connection points. This means that the at least one carrier element rests over a larger area on the connection points, so that improved production of the plug connector in the protective cover during injection molding is possible. The protective layer can be made, for example, from a protective varnish that can be printed onto the at least one carrier element.

In particular, the thickness of the protective layer corresponds to the height of the electrical contacts that projects beyond the at least one carrier element. This means that the at least one carrier element rests firmly on the connection points, so that improved production of the plug connector in the protective cover during injection molding is possible.

The electrical contacts of the at least one carrier element, for example in circuit boards, are usually made of copper and cross the at least one carrier element, forming paths and fields on the surfaces of the at least one carrier element, which protrude slightly on both sides of the at least one carrier element . On the side facing the connection points of at least one Carrier element can pose the problem that the comparatively sharp-edged copper contacts can cut or damage the connection points printed with a silver paste, for example, during the injection molding process. It is therefore preferably proposed that the electrical contacts protrude beyond the side of the at least one carrier element facing the connection points and are framed in their peripheral regions by a protective layer whose thickness corresponds to the height of the electrical contacts projecting beyond the at least one carrier element.

Preferably, the at least one carrier element is provided on the side facing away from the connection points with a layer of an adhesion promoter that promotes injection molding with the plastic. The use of an adhesion promoter is generally known in injection molding. In the present case, the adhesion promoter promotes the bond between the at least one carrier element and the injection molding compound during the injection molding process. The choice of adhesion promoter depends on the at least one carrier element used and the plastic used.

The electrically conductive material connecting the electrical contacts to the connection points preferably has anisotropic conductivity. The anisotropy of the conductivity maximizes the current density of the conducted current in the direction relevant for the contacting, namely in the direction crossing the at least one carrier element, perpendicular to the at least one carrier element, and can either be a material-related property of the material, or through structured application of the material can be achieved on the side of the at least one carrier element facing the connection points.

In particular, the electrically conductive material connecting the electrical contacts to the connection points has an anisotropic conductivity with a maximum conductivity in the direction perpendicular to the at least one carrier element. The anisotropy of the electrically conductive material is particularly advantageous for embodiments in which the

Heating elements are arranged on a carrier film, and their Connection points on the carrier film form adjacent contact areas. In this case, when the electrically conductive material is applied to the contact areas, there could be a risk of a short circuit, which is reduced or eliminated by the anisotropic conductivity with a maximum conductivity in the direction perpendicular to the at least one carrier element.

Preferably, the anisotropic conductivity is a material-related property of the electrically conductive material. If the anisotropy is a material-related property of the electrically conductive material, the electrically conductive material can be applied over the entire surface to the contact areas because the current flow between two adjacent connection points, i.e. parallel to the at least one carrier element, is excluded due to the material.

Preferably, the anisotropic conductivity is caused by structured application of the electrically conductive material on the side of the at least one carrier element facing the connection points. If the electrically conductive material is not already anisotropic in terms of its electrical conductivity due to the material, the anisotropic conductivity can also be achieved by structured application of the electrically conductive material on the side of the at least one carrier element facing the connection points, in that each connection point is over the electrically conductive Material is connected to the electrical contact of the at least one carrier element assigned to it, but not to the other connection points.

The heating elements are preferably arranged on a further, in particular flat, support element. The heating elements are arranged on a flat carrier for the execution of a molded part according to the invention, for example on the carrier film mentioned at the beginning.

In particular, the heating elements are applied to the further support element by screen printing, so that they are easy to produce. Preferably, the at least one carrier element has openings running in a perpendicular direction to the at least one carrier element. These openings enable the injection molding compound to pass through the at least one carrier element during the injection molding process and thus a better bond with the carrier film of the heating elements.

Preferably, at least one temperature sensor is present, which is arranged on the at least one support element. With foil-shaped heating elements, temperature sensors are sometimes used, which are arranged on the carrier foil. The temperature sensors (such as SMD components) are marked by bulges on the carrier film after the injection molding process. In the context of the present invention, the at least one carrier element of the contacting element can be used as a carrier for temperature sensors, so that their arrangement on the carrier film can be dispensed with. The temperature sensors can also be printed on the carrier film. These printed sensors have a significantly smaller thickness (<30pm), which means bulges can be avoided.

At least one of the contact pins is preferably provided for the at least one temperature sensor. In particular, the electrical signal of the at least one temperature sensor can be removed via this contact pin. A separate contact pin can therefore be provided for this temperature sensor, via which the electrical signal from the temperature sensor can be picked up. It is therefore suggested that the connector has at least three contact pins. Two contact pins are provided for powering the heating element, and one contact pin, for example, for a temperature sensor.

Preferably, at least one, in particular capacitively detecting, ice sensor is present, which is arranged on at least one of the heating elements. In the context of the present invention, the at least one carrier element of the contacting element can be used as a carrier for the ice sensor, so that their arrangement on the carrier film can be dispensed with. The at least one ice sensor locally detects a drop below the freezing point of the phase transitions in the molding. If there are several ice sensors, the freezing point can be detected locally on the sensor cover. The ice sensors can also be printed on the carrier film. These printed sensors have a significantly smaller thickness (<30pm), which means bulges can be avoided.

At least one of the contact pins is preferably provided for the at least one ice sensor. In particular, the electrical signal of the at least one ice sensor can be removed via this contact pin. Another contact pin can be provided for an ice sensor, which is arranged on the heating element.

Preferably, at least one electrical component from the group of capacitive sensors, pressure sensors, a light source or an electrochromic layer is present, and which is connected to at least one of the contact pins. In this case the connector would have four contact pins. In principle, any number of contact pins can be provided for any number of sensors. This can e.g. B. capacitive sensors, pressure sensors etc. be . Furthermore, other active elements, such as e.g. B. Light sources or electrochromic layers can be integrated.

A manufacturing method according to the invention for producing a protective cover, in particular a protective cover described here, comprises at least the following steps: a. Arranging electrical contacts on at least one carrier element; b. Attaching contact pins to the electrical contacts; c. Arranging the at least one carrier element at connection points for heating elements which are arranged on a further carrier element, at least one contacting element being formed; d. Injection molding of the at least one contacting element with plastic in a tool of an injection molding process, at least one connection sleeve being co-molded, which in particular frames the plurality of contact pins. The plastic molded part therefore has a plug connector with a contacting element and a connecting sleeve into which a corresponding or Complementarily shaped plug can be easily inserted for connecting a power supply. The production of a soldered connection can therefore be omitted when installing the plastic molded parts, which simplifies the assembly effort of the protective covers according to the invention. The connection sleeve is molded onto the plastic molded part and is manufactured at the same time as the molded part in the injection molding process.

Preferably we in step a. a protective layer is applied to one side of the at least one carrier element around the electrical contacts. The protective layer preferably serves as a spacer between the at least one carrier element and the electrically conductive material or the connection points. This means that the at least one carrier element rests over a larger area on the connection points, so that improved production of the plug connector in the protective cover during injection molding is possible.

Preferably in step b. an adhesion promoter is applied to the side with the contact pins of the at least one carrier element. In the present case, the adhesion promoter promotes the bond between the at least one carrier element and the injection molding compound during the injection molding process. The choice of adhesion promoter depends on the at least one carrier element used and the plastic used.

Preferably in step c. the at least one carrier element is attached to the connection points of the heating elements using an electrically conductive material. In particular, the at least one carrier element is glued to the connection points of the heating elements using an electrically conductive adhesive. On the side of the at least one carrier element facing away from the connection points, the contact pins are attached to the at least one carrier element and are electrically and mechanically connected to the connection points via the electrical contacts and the electrically conductive adhesive f. The at least one carrier element with the contact pins glued to the connection points is inserted into the tool Injection molding process and injection molded with the plastic in such a way that the heating element with the connection points and the at least one carrier element is embedded in the plastic, but the contact pins remain free of material at their free ends and protrude from the molded part. As already mentioned, the connection sleeve, which frames the exposed contact pins, is also formed. Together with the connection sleeve, secure contacting can be ensured via the contacting element.

A use according to the invention of the protective cover described here is a detection of fogging and/or snow adhesion to the protective cover, or protection against icing in the mobility sector and/or as interior heating, in particular as heating of liquid tanks. This protective cover can also be used to heat interior plastic components in the mobility sector or Can be used to heat tanks for all kinds of liquids.

The molded part therefore has a plug connector with contact pins and a connection sleeve into which a correspondingly shaped plug for connecting a power supply can be easily inserted. The production of a soldered connection can therefore be omitted when installing the molded parts, which simplifies the assembly effort of the protective covers according to the invention. The connection sleeve is molded onto the molded part and is manufactured at the same time as the molded part in the injection molding process. The contacting element is prepared before insertion into the injection molding tool by gluing the at least one carrier element to the connection points of the heating elements with an electrically conductive material. The type of connection created between the support element and the connection point has proven to be crucial, since high temperatures and high pressure briefly act on the injection molded parts during the injection molding process.

Further advantages, features and details of the invention emerge from the following description, in which exemplary embodiments of the invention are described with reference to the drawings. The list of reference characters, as well as the technical content of the patent claims and figures, is part of the disclosure. The characters are described coherently and comprehensively. The same reference symbols mean the same components, reference symbols with different indices indicate functionally identical or similar components.

The invention is explained in more detail using the following figures using exemplary embodiments. The reference symbol list is part of the disclosure.

Position information such as "top", "bottom", "right" or "left" are each based on the corresponding representations and are not to be understood as restrictive.

Although the invention has been illustrated and described in detail by means of the figures and the accompanying description, such illustration and detailed description are to be understood as illustrative and exemplary and not as limiting of the invention. It is understood that those skilled in the art may make changes and modifications without departing from the scope of the following claims. In particular, the invention also includes embodiments with any combination of features mentioned or shown above for various aspects and/or embodiments.

The invention also includes individual features in the figures, even if they are shown there in connection with other features and/or are not mentioned above. Furthermore, the term “comprise” and derivatives thereof do not exclude other elements or steps. Likewise, the indefinite article “a” or “an” and derivatives thereof does not exclude a large number. The functions of several features listed in the claims can be fulfilled by a unit. The terms “essentially”, “approximately”, “approximately” and the like in connection with a property or a value also define in particular exactly the property or exactly the value. All reference symbols in the claims are not to be understood as limiting the scope of the claims. The invention is explained in more detail below using exemplary embodiments with the aid of the accompanying drawings. This shows the

Fig. 1 a perspective view of an embodiment of a molded part according to the invention,

Fig. 2 a schematic view to explain a first manufacturing step for the contacting element, in which in particular a protective lacquer is applied to the side of the circuit board facing the connection points,

Fig. 3 a schematic view to explain a further manufacturing step for the contacting element, in which contact pins are attached to the side of the circuit board facing away from the connection points and an adhesion promoter is applied to this side,

Fig. 4 a schematic view to explain a further manufacturing step for the contacting element, in which the circuit board is glued to the connection points of the heating elements,

Fig. 5 a schematic view to explain a final manufacturing step for the contacting element, in which the contacting element is encapsulated with plastic to form the connecting sleeve, and the , and

Fig. 6 a view of the board seen from above.

First of all, we refer to Fig. 1 referenced, which shows an embodiment of a molded part according to the invention with heating elements 1 embedded therein, which are shown in dashed lines. In the exemplary embodiment shown, the heating elements 1 are arranged on a flat support 2 (see FIGS. 4 and 5) and applied to the flat support 2 by screen printing. The heating elements 1 are made, for example, from a hardened, silver-based paste, which is applied in a viscous form to the carrier film using screen printing with the desired course and thermally hardened. The strip-shaped heating elements 1 open into connection points 3 (see FIGS. 4 and 5) for connecting a power supply, so that current can flow through the heating elements 1. The heating elements 1 represent an electrical resistance in which electricity is converted into heat and thus form the desired heat source in the present application.

For connecting a power supply, the molded part is manufactured with a plug connector that has contact pins 4 and a connection sleeve 5. A correspondingly shaped plug for connecting a power supply can easily be inserted into this connector, with the contact pins 4 being part of a contacting element, which will be described in more detail. The production of a soldered connection can therefore be omitted when installing the molded parts, which simplifies the assembly effort of the molded parts according to the invention. The connecting sleeve 5 is molded onto the molded part and is produced simultaneously with the molded part in the injection molding process, as will be explained below.

The contacting element is prepared before being inserted into the injection molding tool, as shown in FIG. 2 to 4 is shown. The Fig. 2 shows a schematic view of a first manufacturing step of the manufacturing process for the contacting element, whereby a circuit board 6 with electrical contacts 8 is initially visible, as in FIG. 7 shown schematically. The circuit board 6 is made in a conventional manner from FR4 or as a flexible circuit board from polyimide or PET and is crossed by the electrical contacts 8 ("through-contacted"). The electrical contacts 8 of the circuit board 6 are usually made of copper and form tracks and Fields on the surfaces of the circuit board 6, which protrude slightly beyond the circuit board 6 on both sides. On the side of the circuit board 6 facing the later connection points 3 - the lower side of the circuit board 6 in FIG. 2 - there is a protective layer 7 made of a protective varnish applied, for example printed, the thickness of which approximately corresponds to the height of the electrical contacts 8 projecting beyond the circuit board 6. The protective layer 7 protects the connection points 3, which are usually also printed on, from damage caused by the comparatively sharp-edged copper contacts during the injection molding process. Fig. 3 shows a schematic view to explain a further manufacturing step for the contacting element, in which contact pins 4 are attached to the side of the circuit board 6 facing away from the connection points 3 and an adhesion promoter is applied to this side. The contact pins 4 are soldered to the electrical contacts 8, for example. In the exemplary embodiment shown, the plug connector has four contact pins 4. Two of these contact pins 4 are provided for the power supply of the heating element 1, another contact pin 4, for example, for a temperature sensor and another contact pin 4, for example, for an ice sensor. The adhesion promoter promotes the bond between the circuit board 6 and the injection molding compound during the injection molding process. The choice of adhesion promoter 9 depends on the circuit board 6 used and the plastic used.

Fig. 4 shows a schematic view to explain a further manufacturing step for the contacting element, in which the circuit board 6 is glued to the connection points 3 of the heating elements 1 using an electrically conductive adhesive 10. The type of connection created between the circuit board 6 and connection points 3 of the heating elements 1 has proven to be crucial, since high temperatures and high pressure briefly act on the overmolded parts during the injection molding process. An adhesive connection has proven to be ideal because it has sufficient elasticity to compensate for thermally caused relative movements between the circuit board 6 and the connection points 3 of the heating elements 1 due to different expansions. On the side of the circuit board 6 facing away from the connection points 3, the contact pins 4 are attached to the circuit board 6 and are electrically and mechanically connected to the connection points 3 via the electrical contacts 8 and the electrically conductive adhesive f 10.

With regard to the adhesive 10 for the connection points 3, it is proposed that the adhesive f 10 connecting the electrical contacts 8 to the connection points 3 has an anisotropic conductivity with a maximum conductivity in the direction perpendicular to the circuit board 6. The anisotropy of conductivity maximizes the current density of the conducted current in the direction relevant for the contacting, namely in the direction crossing the circuit board 6, perpendicular to the circuit board 6, and can either be a material-related property of the adhesive 10, or by structured application of the adhesive 10 on the side facing the connection points 3 Board 6 can be reached, as already explained.

The circuit board 6 with the contact pins 4 glued to the connection points 3 is subsequently placed in the tool of the injection molding process and encapsulated with plastic f 11 in such a way that the heating element 1 with the connection points 3 and the circuit board 6 is embedded in the plastic f 11, However, the contact pins 4 remain at least partially free of material and protrude with their free ends from the molded part (see FIG. 5). As already mentioned, the connection sleeve 5, which frames the exposed contact pins 4, is also shaped. Together with the connection sleeve 5, secure contacting can be ensured via the contacting element. As in the Fig. 6, the circuit board 6 has openings 12 running perpendicular to the circuit board 6. These openings 12 enable the injection molding compound to pass through the circuit board 6 during the injection molding process and thus a better bond with the flat support 2 of the heating elements 1.

In the case of flat heating elements 1 , temperature sensors are sometimes used which are arranged on the flat support 2 . In the context of the present invention, the circuit board 6 of the contacting element can be used as a carrier for temperature sensors, so that their arrangement on the flat carrier 2 can be dispensed with. An advantageous placement of a temperature sensor or another SMD (surface mounted device) component is shown in FIG. 6 indicated by the circled area, where through appropriate design of the electrical contacts 8, the contact areas of two electrical contacts 8 come close, namely the one for the mass, which is shown in FIG. 6 is the left outer contact 8, as well as a contact pin 4 for the temperature sensor, which is shown in FIG. 6 is assigned to the left inner contact 8. The one in the Fig. 6 right inner contact 8 could be intended for the contact pin 4 of an ice sensor, for example be . The one in the Fig. 6 shown right outer contact 8 would be intended for the positive pole of the power supply in the exemplary embodiment shown.

The molded part thus has a plug connector with contact pins 4 and connection sleeve 5. A correspondingly shaped plug for connecting a power supply can easily be inserted into this connector. The production of a soldered connection can therefore be omitted when installing the molded parts, which simplifies the assembly effort of the molded parts according to the invention. The connecting sleeve 5 is molded onto the molded part and is produced simultaneously with the molded part in the injection molding process. With the help of the invention, plastic molded parts are provided that are easier to assemble and enable better contact.

This based on Fig. 2 to 5 disclosed manufacturing method for producing the protective cover generally includes the following steps: a. Arranging electrical contacts 8 on at least one carrier element 6; b. Attaching contact pins 4 to the electrical contacts 8; c. Arranging the at least one carrier element 6 at connection points 3 for heating elements 1, which are arranged on a further carrier element 2, at least one contacting element being formed; d. Injection molding of the at least one contacting element with plastic in a tool of an injection molding process, at least one connection sleeve 5 being co-molded, which frames the plurality of contact pins 4. Reference symbol list

1 heating elements

2 flat supports / additional support element

3 connection points

4 contact pins

5 connection sleeve

6 carrier element / circuit board

7 protective layer

8 electrical contacts

9 bonding agents

10 Electrically conductive material/adhesive f

11 plastic f

12 breakthroughs

Claims

Patent claims:

1. Protective cover for sensors in vehicle technology, which is designed as a molded part with several heating elements (1) injection-molded from a plastic (11) and connection points (3) for the several heating elements (1) for connecting a power supply, characterized in that a plug connector is provided, which comprises a contacting element and a connection sleeve (5) formed on the molded part, the contacting element being formed by at least one carrier element (6), in particular by a circuit board, the at least one carrier element (6) being formed by electrical contacts (8). is crossed.

2. Protective cover according to claim 1, characterized in that the electrical contacts (8) on a side of the at least one carrier element (6) facing the connection points (3) are connected to the connection points (6) via an electrically conductive material, in particular an adhesive (10). 3) are connected.

3. Protective cover according to claim 1 or 2, characterized in that the electrical contacts (8) are electrically contacted with contact pins (4) on a side of the at least one carrier element (6) facing away from the connection points (3).

4. Protective cover according to claim 3, characterized in that contact pins (4) protrude from the at least one carrier element (6) and are in particular framed by the connecting sleeve (5).

5. Protective cover according to claim 4, characterized in that the plug connector has at least two, in particular three, contact pins (4).

6. Protective cover according to one of the aforementioned claims, characterized in that the electrical contacts (8) protrude beyond the side of the at least one carrier element (6) facing the connection points (3). Protective cover according to one of the aforementioned claims, characterized in that the electrical contacts (8) are framed in their peripheral areas by a protective layer (7) which, in particular in its thickness, corresponds to the height of the electrical contacts (8) which projects beyond the at least one carrier element (6). ) corresponds. Protective cover according to one of the aforementioned claims, characterized in that the at least one carrier element (6) is provided on the side facing away from the connection points (3) with a layer of an adhesion promoter (9) which promotes injection molding with the plastic (11). Protective cover according to one of the aforementioned claims, characterized in that the electrical contacts

(8) electrically conductive material connecting to the connection points (3) has an anisotropic conductivity, with a maximum conductivity, in particular in the perpendicular direction to the at least one carrier element (6). . Protective cover according to claim 9, characterized in that the anisotropic conductivity is a material-related property of the electrically conductive material. . Protective cover according to claim 9 or 10, characterized in that the anisotropic conductivity is caused by structured application of the electrically conductive material on the side of the at least one carrier element (6) facing the connection points (3). . Protective cover according to one of the aforementioned claims, characterized in that the heating elements (1) are arranged on a further, in particular flat, support element (2) and are applied to the further support element (2) in particular by screen printing. . Protective cover according to one of the aforementioned claims, characterized in that the at least one support element (6) in a perpendicular direction to the at least has openings (12) running through a support element (6).

14. Protective cover according to one of the aforementioned claims, characterized in that at least one temperature sensor is present, which is arranged on the at least one carrier element (6).

15. Protective cover according to claim 14, characterized in that at least one of the contact pins (4) is provided for the at least one temperature sensor, via which in particular the electrical signal of the at least one temperature sensor can be removed.

16. Protective cover according to one of the aforementioned claims, characterized in that at least one ice sensor is present, which is arranged on at least one of the heating elements (1).

17. Protective cover according to claim 16, characterized in that at least one of the contact pins (4) is provided for the at least one ice sensor, via which in particular the electrical signal of the at least one ice sensor can be removed.

18. Protective cover according to one of the aforementioned claims, characterized in that at least one electrical component from the group of capacitive sensors, pressure sensors, a light source or an electrochromic layer is present, and which is connected to at least one of the contact pins (4).

19. Manufacturing method for producing a protective cover, in particular a protective cover according to one of claims 1 to 18, wherein the manufacturing method comprises at least the following steps: a. Arranging electrical contacts (8) on at least one carrier element (6); b. Attaching contact pins (4) to the electrical contacts (8); c. Arranging the at least one carrier element (6) at connection points (3) for heating elements (1) which are arranged on a further carrier element (2), at least one contacting element being formed; d. Injection molding of the at least one contacting element with plastic in a tool of an injection molding process, at least one connecting sleeve (5) being co-molded, which in particular frames the plurality of contact pins (4).

20. Manufacturing method according to claim 19, characterized in that in step a. a protective layer (7) is applied to one side of the at least one carrier element (6) around the electrical contacts (8).

21. Manufacturing method according to claim 19 or 20, characterized in that in step b. an adhesion promoter (9) is applied to the side with the contact pins (4) of the at least one carrier element (6).

22. Manufacturing method according to one of claims 19 to 21, characterized in that in step c. the at least one carrier element (6) is attached to the connection points (3) of the heating elements (1) using an electrically conductive material, in particular glued using an electrically conductive adhesive (10).

23. Use of the protective cover according to one of claims 1 to 18 as a detection of fogging and / or snow adhesion to the protective cover, or as protection against icing of the protective cover in the mobility sector and / or as interior heating, in particular as heating of liquid tanks.