Capacitive distance sensor

• US 9,702,682 B2
• Filed: 03/11/2013
• Issued: 07/11/2017
• Est. Priority Date: 09/10/2010
• Status: Active Grant

• Current Assignee: Brose Fahrzeugteile Se & Co. Kommanditgesellschaft, Bamberg
• Original Assignee: Brose Fahrzeugteile GmbH & Co. KG, Bamberg (Brose Fahrzeugteile GmbH & Co. KG)
• Inventors: Wuerstlein, Holger, Kuhnen, Thorsten
• Primary Examiner(s): Le, Son
• Assistant Examiner(s): Andrews, Brent J
• Application Number:
  US13/793,219
• Publication Number:
  US 20130193989A1
• Time in Patent Office: 1,583 Days
• Field of Search: 324662, 324686
• CPC Class Codes: B60R 19/483 with obstacle sensors of electric or electronic type
• CPC Class Codes: G01B 7/02 for measuring length, width or thickness G01B7/004, G01B7/12 take precedence
• CPC Class Codes: G01B 7/023 for measuring distance between sensor and object G01B7/082 and G01B7/102 take precedence
• CPC Class Codes: G01B 7/044 using capacitive means
• CPC Class Codes: G01B 7/08 using capacitive means
• CPC Class Codes: H03K 17/955 using a capacitive detector
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A capacitive distance sensor is provided. The distance sensor includes a sensor element having an electrically conductive, elongated, flat sensor area which in turn contains a number of holes. The sensor area is completely surrounded by an electrically non-conductive insulating body, with the result that the insulating body completely covers the edge regions of the holes. The sensor element is produced, in particular, by first of all making the holes in the sensor area. In a subsequent step, the sensor area is completely encased by the insulating body which also completely fills the holes in the sensor area.

Claims

1. A capacitive distance sensor comprising:

a sensor element that comprises an electrically conductive, elongated, flat sensor surface,

a plurality of holes formed in the sensor surface; and

an electrically nonconductive insulating body completely enclosing the sensor surface such that the insulating body completely covers edge regions of the holes

wherein the insulating body is in contact with all surfaces of the flat sensor surface.

2. The capacitive distance sensor as claimed in claim 1, wherein the holes are configured as elongated holes and wherein comparatively long axes of the elongated holes extend in a longitudinal direction of the sensor surface.

3. The capacitive distance sensor as claimed in claim 1, wherein the sensor element is flexible.

4. The capacitive distance sensor as claimed in claim 1, wherein the sensor surface is composed of copper.

5. The capacitive distance sensor as claimed in claim 1, wherein at least a portion of the insulating body is composed of PVC.

6. The capacitive distance sensor as claimed in claim 1, wherein the insulating body contains a plurality of cutouts corresponding to the plurality holes, and wherein each cutout extends within one of the holes.

7. The capacitive distance sensor as claimed in claim 6, wherein a cross-sectional area of each cutout has substantially a same shape as that of the respective corresponding hole through which the cutout extends.

8. A method for manufacturing a sensor element for a capacitive distance sensor as claimed in claim 1, the method comprising:

forming a plurality of holes in the flat, elongated sensor surface, composed of the electrically conducive material;

completely enclosing, in a subsequent working step, the sensor surface by an insulating body which is composed of an electrically nonconductive material and which also completely fills the holes of the sensor surface.

9. The method for manufacturing a sensor element as claimed in claim 8, wherein, in a subsequent working step, a plurality of cutouts corresponding to the plurality of holes is made in the insulating body such that each cutout runs within one of the holes, and wherein an edge of the cutout is consistently at a distance from an edge of an associated hole.

10. The capacitive distance sensor as claimed in claim 1, wherein the insulating body directly contacts all surfaces of the flat sensor surface.

11. The capacitive distance sensor as claimed in claim 1, wherein the insulating body bears against all surfaces of the flat sensor surface.

12. The capacitive distance sensor as claimed in claim 1, further comprising a macromelt termination cast on an end of the flat sensor surface.

14. The capacitive distance sensor as claimed in claim 1, further comprising a plurality of fasteners disposed in the plurality of holes.

13. A sensor element, comprising:

an electrically conductive, elongated, flat sensor-surface;

a plurality of holes formed in the sensor surface; and

an electrically nonconductive insulating body completely enclosing the sensor surface such that the insulating body completely covers edge regions of the holes

wherein the insulating body is in contact with all surfaces of the flat sensor.