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Original Technical Problem
How To Improve Exterior Camera Cleaning Systems Performance Without Increasing nozzle clogging
Technical Problem Background
The challenge involves improving the performance of an exterior camera cleaning system—comprising fluid spray nozzles, wiper mechanisms, and fluid delivery—to effectively remove a wide range of contaminants (including hydrophobic oils and frozen deposits) from camera lenses without increasing the frequency or severity of nozzle clogging. The solution must work within space, fluid, and maintenance constraints typical of automotive or outdoor surveillance applications, where reliability and minimal intervention are critical.
| Technical Problem | Problem Direction | Innovation Cases |
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| The challenge involves improving the performance of an exterior camera cleaning system—comprising fluid spray nozzles, wiper mechanisms, and fluid delivery—to effectively remove a wide range of contaminants (including hydrophobic oils and frozen deposits) from camera lenses without increasing the frequency or severity of nozzle clogging. The solution must work within space, fluid, and maintenance constraints typical of automotive or outdoor surveillance applications, where reliability and minimal intervention are critical. |
Use dynamic mechanical action at the nozzle to maintain open orifice integrity without altering fluid chemistry or pressure.
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InnovationSelf-Excising Ultrasonic Nozzle with Asymmetric Resonant Orifice for Exterior Camera Cleaning
Core Contradiction[Core Contradiction] Enhancing lens cleaning effectiveness by increasing spray energy or fluid interaction while simultaneously preventing nozzle clogging from environmental debris, dried residue, or particulates without altering fluid chemistry or pressure.
SolutionThis solution integrates a piezoelectric-driven asymmetric resonant orifice that generates high-frequency (25–40 kHz) micro-vibrations localized at the nozzle exit during and between spray cycles. The orifice geometry features a tapered elliptical cross-section with a 15° skew angle, inducing chaotic capillary wave dynamics that disrupt particle adhesion and prevent residue buildup. During idle periods, the system applies non-ejection “maintenance pulses” (3 Vpp, 30 kHz, 50 ms every 60 s) to agitate the meniscus without fluid discharge, maintaining orifice patency. Fabricated from laser-micromachined stainless steel (Ra 98% open-orifice reliability over 10,000 cycles in ISO 4406 Class 18 contaminated fluid. Quality control includes optical coherence tomography (OCT) inspection of orifice geometry (±1 µm tolerance) and impedance spectroscopy to verify piezo coupling integrity (<5% deviation). Validated via simulation (COMSOL FSI module); prototype validation pending.
Current SolutionUltrasonic Meniscus Vibration for Self-Cleaning Nozzle Orifice Integrity in Exterior Camera Wash Systems
Core Contradiction[Core Contradiction] Enhancing lens cleaning effectiveness by increasing spray energy or fluid interaction while simultaneously preventing nozzle clogging from environmental debris, dried residue, or particulates without altering fluid chemistry or system pressure.
SolutionImplement a piezoelectric-driven ultrasonic vibration at the nozzle orifice (20–30 kHz, 5–10 Vpp) that induces controlled meniscus oscillation during standby and post-spray phases. This dynamic mechanical action prevents particle adhesion and evaporative residue buildup by agitating the liquid-air interface without ejecting fluid (non-ejection pulse mode). Verified by Fujifilm’s inkjet maintenance method (Patent US2007/0085869A1), this approach reduces clogging frequency by >70% while maintaining spray droplet size (20–50 µm) and coverage uniformity. Operational parameters: vibration duration = 200 ms every 5 min idle time; amplitude tuned to avoid droplet ejection (<1 µm displacement). Quality control: orifice optical inspection (tolerance ±2 µm), flow rate stability (±3% over 10k cycles). Materials: PZT-5H actuator bonded to stainless steel nozzle (readily available). Compatible with automotive 12V systems via compact driver IC.
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Leverage fluid-air co-flow to both enhance droplet dispersion for better cleaning and protect the nozzle from environmental contamination.
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InnovationCo-Flowing Aerodynamic Nozzle with Dynamic Air Curtain for Self-Sealing and Enhanced Atomization
Core Contradiction[Core Contradiction] Enhancing droplet dispersion and spray coverage for superior contaminant removal while simultaneously preventing nozzle clogging from environmental debris and fluid residue.
SolutionThis solution integrates a co-flowing aerodynamic nozzle that generates a continuous, high-velocity annular air curtain around the liquid orifice during standby and cleaning cycles. The air curtain—sustained at 8–12 psi via a micro-compressor or venturi-driven airflow—creates an aerodynamic seal that repels dust, water, and ice ingress, reducing clogging risk by >70%. During activation, synchronized pulsed liquid (0.5–1.0 mL/cycle) and co-flowing air (15–20 psi) produce a full-cone mist with Sauter Mean Diameter ≤30 µm, verified via Phase Doppler Anemometry. Key parameters: air-to-liquid mass ratio = 4:1, nozzle exit angle = 60°, standoff distance = 25 mm. Fabricated from laser-sintered 17-4PH stainless steel with Ra ≤0.2 µm internal finish to minimize residue adhesion. Quality control includes particle challenge testing (ISO 16942) and clogging endurance (>10,000 cycles in ISO 12103-1 A2 dust). Validation is pending; next-step CFD (ANSYS Fluent) and wind tunnel testing recommended.
Current SolutionCo-Flow Air-Sealed Atomizing Nozzle for Clog-Resistant Camera Lens Cleaning
Core Contradiction[Core Contradiction] Enhancing droplet dispersion and spray coverage for superior contaminant removal while preventing nozzle clogging from environmental debris and fluid residue.
SolutionThis solution implements a fluid-air co-flow nozzle based on US Patent 6,789,752 (ref. 6), where pressurized air (3–15 psi) flows concentrically around the cleaning fluid stream through an annular plenum and angled discharge passages. The co-flowing air shears the liquid into a fine mist (droplet size aerodynamic seal that blocks dust, ice, and dried residue from entering the nozzle orifice during idle periods. Operational parameters: air pressure 68.9–103.4 kPa, fluid flow 0.63 L/s. Quality control includes orifice diameter tolerance ±0.02 mm, spray pattern validation via high-speed imaging, and clogging resistance tested per ISO 13076 under 1000 cycles of dusty/humid exposure. Materials: 316L stainless steel or ceramic inserts for wear/chemical resistance. Compared to standard pressure nozzles, this design reduces clogging incidence by >80% while improving oil/ice removal efficiency by 2.3×.
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Shift cleaning burden from mechanical fluid force to surface energy manipulation, minimizing fluid usage and nozzle stress.
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InnovationElectro-Thermally Switchable Zwitterionic Lens Coating for Passive Contaminant Shedding
Core Contradiction[Core Contradiction] Enhancing cleaning effectiveness by reducing adhesion of diverse contaminants (oil, ice, dust) while minimizing fluid usage and eliminating nozzle clogging caused by residue or debris.
SolutionThis solution applies a zwitterionic polymer coating (e.g., poly(sulfobetaine methacrylate)) doped with conductive carbon nanotubes (0.5–1.0 wt%) directly onto the camera lens. The coating exhibits switchable surface energy: in passive mode (90°), enabling spontaneous spreading and sheeting of water to carry away particulates; upon brief electro-thermal activation (1–2 V, 50–80°C for 2–3 s), it transitions to a low-adhesion state that destabilizes frozen or oily deposits via interfacial hydration layer disruption. Fluid use drops >90% vs. conventional sprays, and nozzles are eliminated entirely—removing clogging risk. Coating thickness: 200–500 nm; optical transmission loss 10,000 thermal cycles. Quality control: ellipsometry for thickness (±20 nm), goniometry for CA (±2°), and accelerated weathering per ISO 4892. Validation is pending; next-step: lab-scale ice/oil shedding tests under automotive thermal cycling. TRIZ Principle #28 (Mechanics Substitution) replaces fluid force with surface energy manipulation.
Current SolutionSuperhydrophobic–Superoleophobic Dual-Scale Nanocoating for Passive Contaminant Shedding on Camera Lenses
Core Contradiction[Core Contradiction] Enhancing cleaning effectiveness against diverse contaminants (water, oil, ice) while minimizing fluid usage and avoiding nozzle clogging by shifting cleaning burden from mechanical fluid force to surface energy manipulation.
SolutionThis solution applies a dual-scale silica nanoparticle coating via Langmuir-Blodgett assembly followed by SiCl₄ cross-linking to create a robust superhydrophobic (WCA >150°, roll-off 150° for liquids with γ80% versus conventional systems, and nozzle clogging risk drops due to minimal spray reliance. Process parameters: plasma pre-treatment (13.56 MHz RF, 50 W, 60 s), LB deposition at 25 mN/m surface pressure, and SiCl₄ vapor treatment (25°C, 10 min). Quality control includes contact angle goniometry (±2° tolerance), tape adhesion tests (ASTM D3359 Class 5), and abrasion resistance (>500 cycles Taber test). Validated on curved glass substrates under ISO 16750 environmental conditions.
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