Abstract:
A plastic housing having an integrated plug interface with a plastic housing, in which at least one electrically contacted plug pin is held, wherein the at least one plug pin is held in an embedment in the plastic housing and is electrically contacted by contacts of a plug housing. The plug housing and the plastic housing are produced as separate components. They are connected to each other by a material connection.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a plastic housing having an integrated plug interface and a method relating thereto. 
       BACKGROUND INFORMATION 
       [0002]    German patent document DE 197 31 420 A1 discusses a device for pressure measurement. The device described there is used to measure the pressure in the intake manifold of an internal combustion engine and has a carrier designed as a hybrid plate situated in a housing. A first housing space, provided as a pressure space, in which a sensor element situated on the carrier is located, is connectable via a pressure connection to the intake manifold and is sealed off from its surroundings which includes a second housing space using an adhesive. Bond wires, which electrically connect the carrier to a plug part, are situated in the second housing space, which is provided as a bond space. 
         [0003]    German patent document DE 102 23 357 A1 discusses a device for pressure measurement. It has a housing in which a carrier provided with a sensor element and with electrical terminal elements is situated. The housing has a first housing space surrounding the sensor element and connected to a first pressure channel of a first pressure connection and has a second housing space, which surrounds at least the electrical terminal elements and is sealed with respect to the first housing space. The housing additionally has a third housing space, which is sealed with respect to the first housing space and the second housing space and is connected to a second pressure channel of a second pressure connection. 
         [0004]    The pressure sensor housings used today such as sensor housings for pressure sensors are usually injection-molded plastic parts. This means that the sensor housing and a plug housing, together with plug pins, are injected into a plastic mold. The plug housings are high-precision parts, which make high demands on the precision of the pressure sensor housing to be injection molded in one operation, i.e., the sensor housing and the plug housing. As a result, the sensor housing is necessarily also manufactured with high standards regarding its tolerance, even though this is not required. Furthermore, in manufacturing pressure sensors, the finished housing, including the plug housing and sensor housing, passes through a curing oven. The plastics are cured inside the curing oven; this is associated with thermal deformation, which has a negative effect on the plug dimensions, which had previously been strictly accurate. This deformation necessarily occurs in passing through the curing oven and is difficult to prevent in the case of relatively large sensor housings having integrally molded plug housings in particular. Moreover, flexibility is also very limited because a separate sensor housing and a separate injection mold required for same must be manufactured and kept on hand for almost each customer&#39;s plug. 
       SUMMARY OF THE INVENTION 
       [0005]    An object of the exemplary embodiments and/or exemplary methods of the present invention is to provide a housing having an integrated interface, which is manufactured by the plastic injection molding method and has a much greater flexibility with regard to customer&#39;s plug variants and makes lower demands regarding the precision of the mold in which the plastic housing is manufactured. 
         [0006]    The plastic housing may be a housing in which a sensor is accommodated or a housing which holds an actuator for actuating a final controlling element, or the like. 
         [0007]    It is proposed according to the exemplary embodiments and/or exemplary methods of the present invention that a plug interface for contacting a sensor or an actuator be manufactured separately from the plastic housing in which the sensor or actuator contacting the plug interface is accommodated. The plug interface may be welded to the plastic housing forming the base part in a subsequent operation, for example, by the plastic laser welding method. This allows the use of an injection mold having a simpler design for manufacturing the plastic housing and a mold of a simpler design for fabrication of the particular plug interface. 
         [0008]    The approach proposed according to the exemplary embodiments and/or exemplary methods of the present invention increases flexibility due to the possibility of using the customer&#39;s particular plug interface variant, i.e., the injection mold required for manufacturing same, so that a shared mold may still be used for fabrication of the plastic housing. The plug pins may be replaced by replaceable inserts in the mold. With regard to the fabrication of the plastic housing and the plug interface, which is fabricated separately from the former, cost savings may be achieved due to the fact that it is not absolutely necessary to use a separate injection mold for each variant of a plastic housing. 
         [0009]    The approach proposed according to the exemplary embodiments and/or exemplary methods of the present invention allows greater flexibility with regard to the variants of plug interfaces demanded by customers while retaining a housing mold for manufacturing a plastic housing for a sensor or an actuator which is usable for multiple variants. The mold for manufacturing the plug interfaces may have a simpler design, in particular without insertion parts which are usually fabricated from a metallic material and are used to manufacture the plug pins. In comparison with the precision requirements which are made for the plug interface, i.e., the housing, and are necessary to achieve dimensionally more stable plug interfaces, relatively low precision requirements may be made for the mold in comparison with that by fabricating the plastic housing to receive the sensor or the actuator. In addition, when using the approach proposed according to the present invention, redundancy is achieved in sealing the plug pins in the interior of the sensor housing. 
         [0010]    Thus, following the approach proposed according to the exemplary embodiments and/or exemplary methods of the present invention, the plastic housing for holding a sensor or an actuator is manufactured in the housing mold using insert parts for fabrication of the plug pins by the plastic injection molding method. For each variant of a customer&#39;s plug interface, which is to be connected to the plastic housing, the customer&#39;s own plug pins are sheathed by using replaceable insertion parts. This is necessary because plug pins may have various thicknesses, shapes, patterns, surfaces, and materials, as a function of the customer&#39;s requirements. 
         [0011]    Following the approach proposed according to the present invention, the plug interfaces are injected separately from the plastic housing and are manufactured with a high precision due to the simple mold shape. Due to the approach provided by the exemplary embodiments and/or exemplary methods of the present invention of the separate fabrication of the plastic housing to hold a sensor or an actuator and the plug housing, which is a customer-specific design of a plug interface, it is possible to achieve a simpler method of maintaining tolerances, in particular in the fabrication of the plug part, which is to be manufactured to a high precision, so that the plastic housing, which has lower tolerance requirements, may be fabricated to hold a sensor or an actuator of lower tolerance requirements and in particular one and the same injection mold may be used. The precision requirements made for the plug interface on the one hand and the plastic housing on the other hand may thus be uncoupled from one another with regard to the fabrication. Furthermore, the geometry in which the plastic housing is fabricated is simplified by separating the fabrication of the customer-specific design of the plug part forming the plug interface, so that smaller base bodies may be used and a fabrication that is more suitable for plastics is implementable. 
         [0012]    The plug housing, which forms the plug interface and is fabricated separately, is attached to the plastic housing, which is fabricated separately and is pressed as far as a stop, for example. This means that the plug pins attached to the plastic housing are surrounded by the plug housing and may push through it. In assembly, the plug pins of the plastic housing for receiving a sensor or an actuator pass through the bottom face of the plug housing representing the plug interface. In pushing through the bottom surface of the plug housing, for example, the plug pins may be additionally sealed by displaced material at the particular passages. The plug housing may be bonded to the plastic housing on its lateral surface, for example, by laser welding along the circumference and thus joined mechanically to the plastic housing, which is manufactured separately and forms a basic module. 
         [0013]    The plastic housing to receive a sensor or an actuator and the plug interface as proposed according to the present invention being designed as separate parts advantageously ensures that the plug pins embedded in the plastic housing, which forms a basic module, are sheathed in the plastic housing on the one hand while on the other hand they may be additionally sealed in the assembly of the plug housing by pushing through the bottom of the plug housing, so that there is redundant sealing of the plug pins. 
         [0014]    The exemplary embodiments and/or exemplary methods of the present invention is described in greater detail below on the basis of the drawings on the example of a pressure sensor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  shows a component made up of a plug part and a housing part designed in one piece. 
           [0016]      FIG. 2  shows a section through the plug part of the sensor component designed in one piece according to the diagram in  FIG. 1 . 
           [0017]      FIG. 3  shows a perspective top view of a separate plug housing representing a plug interface in a first embodiment variant, bonded to a plastic housing to receive a sensor. 
           [0018]      FIG. 3.1  shows a section through the bonded connection between the plug housing in the first embodiment variant and the plastic housing as shown in  FIG. 3 . 
           [0019]      FIG. 4.1  shows another embodiment variant of the plug housing. 
           [0020]      FIG. 4.2  shows another variant of the plug housing. 
           [0021]      FIG. 4.3  shows the plug housing in its first specific embodiment as shown in  FIG. 3  in the materially joined state. 
           [0022]      FIG. 4.4  shows a front view of the plastic housing to receive a sensor or an actuator having plug pins surrounded by a border for electrical contacting. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    The diagram according to  FIG. 1  shows a sensor component designed in one piece, as is known from the related art. 
         [0024]    As shown by the perspective diagram according to  FIG. 1 , sensor component  10  designed in one piece as a plastic injection-molded component has a plug part  12  and a housing part  14 , which are designed to merge into one another. A catch nose  16  is provided on plug part  12 . Plug part  12  surrounds plug pins  18 , which are discernible in the sectional diagram according to  FIG. 2 . The plug part of the sensor component designed in one piece according to the diagram in  FIG. 1  includes a plug opening  20  into which a plug is inserted and on which catch nose  16  may be lockingly engaged. 
         [0025]      FIG. 2  shows a sectional diagram through sensor component  10  according to the diagram in  FIG. 1 .  FIG. 2  shows plug pins  18  embedded in the plastic material of sensor component  10 . The embedding to receive plug pins  18  is labeled with reference numeral  22 . Reference numeral  24  denotes the shared wall of housing part  14  and plug part  12  of sensor component  10 , which is designed in one piece. The one-piece design of the sensor component in  FIGS. 1 and 2  has the disadvantage that although plug part  12  is fabricated to relatively high precision requirements to receive the plug having a customer-specific design and initially has a high dimensional stability, it is subject to thermal deformation in a curing process in a curing oven. With respect to housing part  14  of sensor component  10 , which is designed in one piece, the thermal deformation, which occurs during passage through the curing oven due to the higher temperatures prevailing there, is of subordinate importance; however, the thermal deformation has substantial effects with respect to plug part  12  of sensor component  10 , which is designed in one piece, in particular with regard to the dimensional stability which has previously been established in a tedious operation. With regard to the fabrication of sensor component  10 , which is designed in one piece according to the diagrams in  FIGS. 1 and 2 , it may be stated that the plastic injection mold, in which sensor component  10 , which is designed in one piece, together with plug part  12  and housing part  14  is fabricated, is inflexible with regard to retrofitting to customer-specific differences in configuration of plug parts  12 . Therefore, relatively high retrofitting and mold costs are unavoidable with respect to the injection mold used in the approach having a sensor component  10  designed in one piece. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    The diagrams in FIGS.  3  and  3 . 1  show plastic housings fabricated separately from one another and then joined together for a sensor or an actuator or a plug housing in a first embodiment variant. 
         [0027]      FIG. 3  shows that a plug housing  36  in the first embodiment variant may have catch nose  16  on its top side and, if necessary, another lower catch engagement  64  on its bottom side. Reference numeral  60  denotes catch noses situated on the side. In the first embodiment variant, longitudinal ribs  72  run on a lateral surface  58  of plug housing  36 . Longitudinal ribs  72  function as a guide for a mating plug, which is not shown in the diagram according to  FIG. 3 . 
         [0028]    As also shown in the diagram according to  FIG. 3 , a border  50  is extruded on plastic housing  30  to receive a sensor or an actuator. Border  50  surrounds a receptacle opening  34 , which is best shown in the sectional diagram according to  FIG. 3.1 . Although plug housing  36  in its first variant is fabricated in a separate injection mold to high precision requirements for the resulting injection-molded component, plastic housing  30  may be manufactured less expensively in an injection mold because the tolerances required are much lower due to the smaller and overall less complex geometry of the injection mold, in which plastic housing  30  is fabricated separately in comparison with the tolerances required of the fabrication of plug housing  36  as well as its further embodiment variants in an injection mold. 
         [0029]      FIG. 3.1  shows a sectional diagram of the sectional components joined together according to  FIG. 3 , namely the plug housing in the first embodiment variant and the plastic housing to receive a sensor or an actuator. 
         [0030]      FIG. 3.1  shows that plug housing  36  in the first embodiment variant is fitted into receptacle opening  34  of plastic housing  30 . A fit which is established between a bottom part  40  of plug housing  36  in the first embodiment variant and the boundary of receptacle opening  34  is identified by reference numeral  38  in the sectional diagram according to  FIG. 3.1 . 
         [0031]      FIG. 3.1  shows that plug pins  18  may be pushed through openings  42  in the bottom part of plug housing  36  when plug housing  36  is assembled in the first embodiment variant according to  FIG. 3.1  in receptacle opening  34 . In pushing through at least one opening  42  for at least one plug pin  18 , which is accommodated in embedding  32  in plastic housing  30  to receive a sensor or an actuator, a seal  44  is formed around plug pins  18  passing through openings  42 . 
         [0032]    When plug pins  18  are optionally pushed through at least one opening  42  in bottom part  40  of plug housing  37  in the first specific embodiment, the plastic material bordering at least one opening  42  in bottom  40  is deformed and forms seal  44  around individual plug pins  18 . The approach of manufacturing plastic housing  30  and plug housing  36  separately in different specific embodiments, as proposed according to the present invention and explained below, allows redundant sealing of plug pins  18 , first in embedding  32  of plastic housing  30  and secondly in seal  44  in bottom part  40  of plug housing  36  in the first embodiment variant. The projecting portion by which the ends of plug pins  18  protrude above bottom part  40  through openings  42  may be adjusted through the design of the height of bottom part  40  of plastic housing  30  to receive an actuator or a sensor. 
         [0033]    The sectional diagram in  FIG. 3.1  shows a longitudinal rib  52 , which assumes the function of a spacer for a mating plug. Damage to or bending of plug pins  18  when plug housing  36  is manufactured in receptacle opening  34 , bordered by border  50 , of plastic housing  30  to receive a sensor or an actuator is/are prevented by at least one longitudinal rib  52 , which is formed on lateral surface  58  of plug housing  36  in its first specific embodiment. 
         [0034]    The sequence of  FIGS. 4.1 ,  4 . 2 , and  4 . 3  shows, as an example, various embodiment variants of the plug housing to be fabricated separately from the plastic housing to receive a sensor or an actuator, as proposed according to the present invention. 
         [0035]      FIG. 4.1  shows the plug housing in a first specific embodiment  36  having catch nose  16  and lower catch engagement  64  opposite the former. Plug opening  20  may optionally be provided with a tapered edge  70  to allow easier insertion of the electrical plug, which has been finished according to customer-specific requirements. As also shown in the perspective diagram in  FIG. 4.1 , at least one longitudinal rib  52  runs on lateral surface  58  of plug housing  36  in the first embodiment variant. Longitudinal rib  52  extends for a defined length on lateral surface  58 . Two, four, or more, longitudinal ribs  52  may be provided on lateral surface  58  of plug housing  36  in the first embodiment variant. In third embodiment variant  72  of the plug housing shown in  FIG. 4.3 , peripheral collar  56  has the function of limiting the depth of immersion. In the embodiment variant of plug housing  54  shown in  FIG. 4.2 , the depth of insertion of bottom part  40  of the plug housing in second specific embodiment  54  is defined by the axial length of bottom part  40  and the shoulder adjacent thereto in lateral surface  48  of the plug housing in second embodiment variant  54 . 
         [0036]      FIG. 4.2  shows another possible specific embodiment of the plug housing, shown here in a second embodiment variant. 
         [0037]      FIG. 4.2  shows plug housing  54  in a second specific embodiment. This customer-specific embodiment of plug housing  54  is injected in a plastic injection mold, thus ensuring a high dimensional stability by the single- or two-component injection molding method. Numerous guide ribs  62  extending axially to lateral surface  58  of plug housing  54  in the second embodiment variant are provided on lateral surface  58  of plug housing  54  in the second specific embodiment. In addition, catch nose  16  is situated between ribs  62 . If necessary, a tapered edge  70  may be provided on the border of plug opening  20 , allowing simple insertion of the customer-specific plug into plug opening  20 , which is delimited by inside wall  68 . A hollow space  66 , which is surrounded by inside wall  68  of plug housing  54  in the second embodiment variant, is much larger in comparison with the third embodiment variant of plug housing  72  shown in  FIG. 4.3 . 
         [0038]    Bottom part  40 , which is inserted into receptacle opening  34  of sensor housing  30  shown in  FIG. 3.1  in a sectional view and in a perspective top view in  FIG. 4.4 , is extruded onto an end face of the plug housing in second specific embodiment  54 . 
         [0039]      FIG. 4.3  shows a possible third variant of plug housing  72 , which has a peripheral collar  56  in addition to catch nose  16  and a lower catch  64  situated opposite the former on lateral surface  58 . Peripheral collar  56  determines the depth of immersion by which the bottom part of plug housing  72  in the third specific embodiment is inserted into receptacle opening  34  of plastic housing  30  to receive a sensor or an actuator, shown in a sectional view in  FIG. 3.1 . Reference numeral  68  refers to an inside wall of plug housing  72  in the third embodiment variant. A customer-specific plug designed to be complementary to the particular specific embodiment of plug housing  72  is inserted into plug opening  20 . This establishes electrical contact with plug pins  18  surrounded by lateral surface  58  of plug housing  72  in the third specific embodiment. 
         [0040]      FIG. 4.4  shows a perspective view of the plastic housing, which is fabricated separately from the plug housing for receiving a sensor or an actuator. 
         [0041]      FIG. 4.4  shows that receptacle opening  34  is surrounded by border  50 . According to the perspective top view in  FIG. 4.4 , three plug pins  18  situated side by side are embedded in the material of plastic housing  30  to receive a sensor or an actuator. Embedding  32  is best shown in the sectional diagram in  FIG. 3.1 . To facilitate assembly of bottom part  40  of each specific embodiment of plug housing  36 ,  54 ,  72 , which is fabricated separately, in receptacle opening  34  of plastic housing  30 , a tapered edge  70  is provided on border  50  of receptacle opening  34 , facilitating tilt-free insertion of bottom part  40  and ensuring undamaged insertion, i.e., pushing of plug pins  18  through at least one opening  42  in bottom part  40  of plug housing  36 ,  54 ,  72  in its various specific embodiments. 
         [0042]    Plastic housing  30  according to the diagrams in  FIGS. 3 and 4  is fabricated together with the insertion of plug pins  18  into the injection mold to manufacture plastic housing  30 . For each customer-specific plug variant, separate plug pins  18  must also be sheathed by a replaceable insert (insertion part). Customer-specific plug pins  18  have variable thicknesses, shapes, patterns, surfaces, and materials. Plug housings  36 ,  54 ,  72  in the specific embodiments are plug interfaces, which are fabricated separately in separate molds by the injection molding method and may be manufactured to a high precision by using a smaller and simpler mold, regardless of the lower tolerance requirements of plastic housing  30  to receive the sensor or the actuator. The dimensional stability requirements to be made for plug housings  36 ,  54 , and  72  in the various embodiment variants are much higher in comparison with the mold used for manufacturing plastic housing  30 . When plug housings  36 ,  54 , and  72 , which form the plug interface in the various embodiment variants are assembled, the plug housings are attached to plastic housing  30  to receive an actuator or a sensor and are pressed into receptacle opening  34 . Plug pins  18  are additionally sealed by pressure on their openings  42  (cf. reference numeral  44  in the sectional diagram according to  FIG. 3.1 ). Plug housing  36 ,  54 ,  72 , which forms the customer-specific plug interface, is bonded to plastic housing  30  to receive a sensor or an actuator, i.e., its border  50  (cf. item  48  in  FIG. 3 ). There is thus a mechanical connection between plug housing  36 ,  54 ,  72 , which forms the plug interface, and plastic housing  30 , which forms the basic module. 
         [0043]    The approach of manufacturing plug housing  36 ,  54 ,  72  independently of plastic housing  30  to receive a sensor or an actuator, as proposed according to the present invention, allows greater flexibility in customer variants, in particular in the case of plug geometries of various designs. Plastic housing  30  of the same design may ideally always be used. The approach proposed according to the present invention results in injection molds of a smaller and simpler design and a higher precision in manufacturing the plug interfaces formed by the various sensor housing variants. 
         [0044]    Although the requirements of plastic housing  30 , which always has essentially the same design, to receive a sensor or an actuator always remain the same, the more complex plug geometries for plug housings  36 ,  54 , and  72  may be constructed in separate but smaller molds as a function of customer specifications. Much greater tolerance demands are made for these customer-specific designs for the injection molds for manufacturing plug housings  36 ,  54 , and  72  in comparison with the requirements for the mold for manufacturing plastic housing  30  to receive the sensor or the actuator.