Sensor assembly comprising a cover element, and method for producing a cover element of a sensor assembly of a motor vehicle

A method for producing a cover element of a sensor assembly of a motor vehicle, the method comprising the following steps:

• providing a backing film having a first side and a second side;
• applying, a plurality of conductor paths and at least two bus bars to the first side of the film;
• introducing, the backing film with the conductor paths into a cavity of an injection mold in such a manner that the two bus bars protrude over the conductor paths;
• filling the cavity of the injection mold with at least one plastic material in such a manner that the two bus bars each form an electrical connecting element which remains free from the plastic material;
• hardening the plastic material in the cavity for forming the cover element having the backing film molded thereto;
• and demolding the cover element with the backing film molded thereto.

A sensor assembly of a motor vehicle, the sensor assembly comprising:

• at least one sensor element emitting and/or detecting electromagnetic radiation in at least one measuring direction to determine a measuring signal,
• a cover element disposed in front of the sensor element in the at least one measuring direction and being an injection-molded plastic part which has at least one layer and is transparent to the electromagnetic radiation, and
• a heating feature comprising a plurality of conductor paths applied to a backing film molded to the cover element, the backing film including the conductor paths thus forming an insert of the injection-molded cover element, the conductor paths being located on the side of the backing film facing the sensor element,
• wherein the conductor paths are connected to each other in an electrically conductive manner by at least two bus bars and the at least two bus bars each at least partially form an electrical connecting element protruding from the cover element and being exposed so that electrical contact can be made with the electrical connecting elements, and
• wherein each of the electrical connecting elements is formed by a portion of a respective bus bar that remains free of the injection-molding plastic of the cover element.