Sensor bracket for vehicle

Abstract

The present invention relates to a sensor bracket (10) for a vehicle, in particular for being arranged behind a bumper (12) of a vehicle. The sensor bracket (10) comprises at least one receiving area (14) for accommodating a sensor (16) and at least one fixing area (18), by which the sensor bracket (10) can be fixed to an additional element, in particular to the bumper (12). At least a portion of the at least one fixing area (18) comprises an attachment area (20) for fixing to the additional element. The present invention proposes that at least one overhanging portion (22) is arranged between the attachment area (20) and the receiving area (14) on the at least one fixing area (18). The present invention also relates to an assembly consisting of such a sensor bracket (10) arranged on a bumper.

Description

Technical Field

[0001] The present invention relates to a sensor bracket for a vehicle, in particular to a sensor bracket arranged behind a vehicle bumper.

[0002] Furthermore, the invention relates to an assembly in which a sensor holder with a sensor is arranged on a bumper. Background Art

[0003] For example, prior art documents such as EP 3 473 499 A1, FR 2 987 400 A1, US Pat. No. 8 894119 B1, and FR 2 986 483 A1 disclose fasteners for sensors that allow them to be mounted, for example, behind a vehicle's hull. The fasteners are designed to allow the sensor to be positioned as close as possible to the vehicle's hull. The sensor may be a radar sensor, such as a medium-range radar sensor (MRR sensor), used to monitor the area in front of or behind the vehicle for driver assistance systems, such as lane-crossing warning systems, programs for assisting in exiting parking spaces, blind spot assistance systems, or the like. Such sensors, particularly useful in autonomous driving applications, are relatively large, with their housing typically having a rectangular or square shape and dimensions between 5 x 5 cm and 10 x 10 cm, or larger, such as approximately 6 x 9.5 cm. Their mass is such that, in the event of a collision with the mounting structure, the impact forces are applied to the sensor mount. Thanks to its fastening method, the sensor's receiving or radiating field can be precisely adjusted without being affected. It is expected that the sensor's alignment in the sensor holder will deviate by less than 3° over a service life of several years.

[0004] Once installed, the sensors should be kept as small as possible from their mounting position to avoid affecting the measured values ​​recorded or received by the sensors. First, the mounting structure must be sufficiently rigid. The sensors are mounted, for example, within the vehicle's exterior, using a sensor bracket. Multiple sensors are regularly arranged on the inner surface of the bumper. These sensors are held in the sensor bracket at a predetermined distance from the bumper's inner surface and, using the sensor bracket, are aligned in positions determined relative to the vehicle's longitudinal axis. Consequently, the sensors are not located directly on the inner surface of the bumper.

[0005] The nature of the various collisions a vehicle must withstand is described in standards known to the industry as part of technical specifications binding on all manufacturers.

[0006] These technical specifications consider four main categories of collisions, namely:

[0007] - High-speed collisions, equivalent to head-on collisions against rigid or deformable obstacles. For head-on collisions, the vehicle speed must be at least 56 km / h. Therefore, the vehicle must be designed to protect the vehicle occupants.

[0008] - Insurance-type collisions, hitting a fixed wall at a speed of about 15 km / h, such as the so-called Danner collision or AZT collision, or hitting a deformable barrier or pole at a speed of about 10 km / h (RCAR bumper test, pole collision, IIHS standard), the goal of dealing with this type of collision is to limit damage and related repair costs.

[0009] - Small collision or parking collision (ECE42, USPART 581), the center speed is about 4km / h, the corner speed is about 2.5km / h, and the treatment goal is to ensure that there is no external damage to the bumper skin.

[0010] - Pedestrian collisions (leg, femur), at speeds of approximately 40 km / h, should be handled in a biomechanically compliant manner to reduce pedestrian injuries.

[0011] In the event of a minor collision (eg a parking collision or a pedestrian collision), the sensor holder must be able to elastically dampen the impact and not be damaged or deflected in such a way as to impair the functioning of the sensor, in particular with regard to its orientation.

[0012] To check the rigidity and stability of the sensor's mounting on the housing, a crash test can be performed, corresponding to a minor collision, such as a parking collision or pedestrian collision. In this case, the sensor mounted on the sensor bracket is subjected to a projectile impact (French: collision d'un projectile). The crash test can be performed, for example, with a projectile. In this case, the impact is preferably centered and perpendicular to the sensor surface. If the sensor with the sensor bracket is mounted on the inner surface of the bumper, the impact is approximately perpendicular to the bumper surface. When the projectile impacts the sensor, it deflects in the direction of impact. In this case, the extent to which the sensor returns to its original position after being deflected by the impact is tested. Furthermore, the sensor bracket is checked to see if it has permanently or irreversibly detached from the inner surface of the bumper. The sensor bracket should be designed so that, after deflection, the sensor returns to its original position only after the change in position or angle is as small as possible and does not become loose from the bumper interior. For example, in the prior art, a support device is located behind the sensor on a rear-facing component of the vehicle to prevent it from deflecting in the direction of the impact.

[0013] With newer sensors, particularly those used in driver assistance systems, rear support for the sensor bracket isn't always possible, for example, because the space behind the bumper doesn't allow for or doesn't provide support structures at the sensor's required location. For example, sensors used in driver assistance systems, such as medium-range radar sensors (MRR sensors), are mounted only at a distance from the sensor bracket on the inner surface of the bumper. The rear support structure is limited to a maximum of 120 mm, forcing the sensor to be secured almost in a cantilevered manner. Because these sensors perform multiple functions for autonomous driving, they are relatively large and are typically secured to the inner surface of the bumper via multiple welds. When the sensor bracket and bumper are made of different materials (especially different plastics), the welds are less crash-resistant than welds made of the same materials. For example, the sensor bracket can be made of a harder material than the bumper, especially a different plastic. Consequently, the welds are less stable. Even sensors mounted this way must successfully pass the aforementioned crash tests. This means that after an impact, the sensor must return to its original position. Therefore, the sensor bracket itself must provide sufficient stability and securement. Summary of the Invention

[0014] Therefore, an object of the present invention is to provide a sensor bracket that overcomes the above-mentioned disadvantages.

[0015] This object is achieved by a sensor holder for a vehicle, in particular for arrangement behind a bumper of a vehicle, comprising at least one receiving area for accommodating a sensor and at least one fastening area, via which the sensor holder can be fastened to an additional element, in particular to a bumper, and comprising, on at least one portion of the at least one fastening area, an attachment area for fastening to the additional element, wherein at least one overhanging portion is arranged on the at least one fastening area between the receiving area and the attachment area. The at least one overhanging portion serves, for example, as a crash buffer which returns to its original position, i.e., elastically, after absorbing the energy of an impact.

[0016] Other optional features that can be used individually or in combination depending on the sensor holder:

[0017] - said at least one suspended portion is elastic;

[0018] - “crash-resistant” should be understood as resistant to minor collisions (such as parking collisions or pedestrian collisions);

[0019] - the at least one suspended portion is impact-resistant and reversible in position;

[0020] - the at least one suspended portion is more elastic than the attachment area and the receiving area;

[0021] a plurality of fixing regions are provided in the sensor holder, wherein at least one fixing region forms at least one tongue, said at least one tongue comprising a hanging portion for connecting the attachment region to the receiving region;

[0022] the at least one suspension part and the at least one fastening region, in particular the tongue, are formed as a single piece, the suspension part preferably being formed as a solid body hinge (articulation à corps solide in French), in particular as a material embossing (gaufrage de matériau in French) and / or a material bend;

[0023] - the suspension has different zones, one zone designed to compensate for longitudinal and lateral displacements respectively, and another zone designed to compensate for rotations;

[0024] the overhanging portion is at least partially formed with a thinned cross section, the cross section at least partially having a wall thickness that is smaller than the wall thickness in the overhanging portion, in particular the wall thickness in the overhanging portion is each smaller than the wall thickness of the cross section in the region of the at least one fixing region;

[0025] the at least one overhanging portion extends over the entire width of the at least one fixing region, in particular over the entire width of the tongue, preferably the at least one overhanging portion having a small width, which is preferably at least less than one fifth, in particular one eighth, of the length of the at least one fixing region;

[0026] - the width of the fixing area, in particular the width of the tongue, is formed to narrow in the area of ​​the hanging part;

[0027] - at least one suspended portion is designed to absorb shear forces, preferably elastically;

[0028] - a shear force acts on the sensor holder after the sensor inserted into the receiving area is subjected to a predetermined load, wherein the load is applied perpendicularly to the front face of the sensor, preferably corresponding to a load resulting from a parking collision or a pedestrian collision;

[0029] - said receiving area is formed integrally with said at least one fixing area;

[0030] the receiving area comprises a receiving cavity which is open on at least one side, the at least one fastening area being arranged on the open side of the receiving cavity and the connection of the attachment area to the receiving area being formed by the overhanging portion, the receiving cavity not overlapping the at least one fastening area, in particular in the direction of the sensor;

[0031] - the connection of the attachment area to the receiving area is collision-resistant and positionally reversible;

[0032] - the connection of the attachment area to the receiving area is elastic;

[0033] - the receiving area has a substantially basin-like shape, and the at least one fixing area is connected to the receiving area in the area of ​​its upper edge;

[0034] The attachment area is designed as a raised surface in the fastening area, which is machined as a welding surface, in particular in the form of a welding plate. The presence of this raised surface ensures that the movement of the suspension part during a crash does not damage the fastening provided by the welding;

[0035] - The raised surface is used as a welding surface;

[0036] The sensor holder comprises at least three, in particular four, fastening regions, wherein at least two, in particular three, of the fastening regions have suspension portions which are arranged away from the receiving region in order not to affect the movement of the sensor;

[0037] The sensor holder consists of a glass-fiber-loaded elastomer, in particular an elastomer from the group consisting of PP / EPDM, with a glass fiber content preferably of at least 5%, the sensor holder being more rigid than an additional element to which it may be fastened, in particular a bumper;

[0038] -The sensor bracket is suitable for manufacturing by injection molding;

[0039] - the at least one receiving area is configured to accommodate at least one sensor;

[0040] - the at least one receiving area is configured to accommodate a single sensor;

[0041] - The at least one receiving area is configured to accommodate a plurality of sensors.

[0042] The object is also achieved by an assembly consisting of a sensor bracket of the above type arranged on a bumper, wherein the sensor bracket is fixed, in particular welded, to the inner surface of the bumper at the at least one attachment area, and the sensor is accommodated in the sensor bracket and arranged between the inner surface of the bumper and the sensor bracket, and is fixed relative to the inner surface of the bumper by a suspension portion.

[0043] Other optional features that may be used individually or in combination depending on the component:

[0044] -The suspension part is elastic;

[0045] - “crash-resistant” is understood to mean resistant to minor collisions (e.g. parking collisions or pedestrian collisions);

[0046] - The suspension is collision-resistant and reversible;

[0047] - The component is collision resistant.

[0048] The present invention relates to a sensor bracket for a vehicle, in particular a sensor bracket for arrangement behind a vehicle bumper. The sensor bracket comprises at least one receiving area for accommodating a sensor and at least one fastening area, via which the sensor bracket can be fastened to an additional element, in particular to the bumper. At least a portion of the at least one fastening area comprises an attachment area for fastening to the additional element.

[0049] At least one impact-resistant and reversible suspension portion is arranged on at least one fastening area between the receiving area and the attachment area. The sensor is aligned with the aid of the sensor holder in an alignment position defined relative to the vehicle axis and generally does not contact an additional element to which the sensor holder can be fastened. Thanks to the at least one suspension portion, the sensor arranged in the receiving area can automatically return to its initial position with the aid of the sensor holder if it deviates from the rest position, for example in the event of an impact on an additional element, such as a bumper. This is achieved in particular by the fact that the suspension portion is elastic on the one hand and reversible on the other. In this case, the suspension portion can be stretched and preferably returns to its initial position on its own. For example, the suspension portion can be made of a shape-memory material. Preferably, the suspension portion is formed from a plastic material.

[0050] In a crash test as described above, a sensor is struck by a projectile (e.g., a bullet) perpendicular to the sensor. Following the collision, the sensor, mounted in the sensor bracket, deflects from its resting position. This results in deformation of the bumper, preferably to which the sensor bracket is attached, as well as deformation of the sensor bracket itself. This deflection of the sensor bracket can generate shear forces in at least one attachment area. If these forces exceed a certain limit, the sensor bracket could permanently or irreversibly detach from the bumper. To avoid this, the forces generated by the collision can be absorbed by the suspension portion. Preferably, substantially all of the forces in the suspension portion are offset by its deformation. Due to this deformation, the sensor initially deflects and then returns to its original position. This, on the one hand, reduces the load on the attachment area, and on the other hand, ensures that the sensor remains firmly positioned and in its intended position. This makes it possible to maintain the permissible tolerance for sensor alignment in the resting position. For example, the maximum permissible tolerance could be 3°. This corresponds to the maximum permissible tolerance over a five-year period. In this regard, the suspension portion of the sensor bracket ensures an optimal balance between alignment, stability, and flexibility in response to impacts applied to the sensor.

[0051] This sensor holder is particularly suitable for larger and heavier sensors. Thus, the sensor can have a rectangular or square shape, for example, with side edges preferably measuring between 6 and 9 cm. For example, one side edge can measure 6 cm, while the other side edge can measure 9 cm. The sensor thickness can particularly be between 1 cm and 5 cm. Preferably, the sensor has a thickness of approximately 2 cm and a weight between 50 g (grams) and 150 g, particularly between 80 g and 90 g.

[0052] The hanging part is preferably arranged in the fixing area, between the attachment area and the receiving area. In this case, the size of the hanging part is relatively small in at least one spatial direction relative to the overall size of the fixing area so that the hanging part requires as little installation space as possible.

[0053] The suspension part can be designed, for example, as a peripheral structure extending around the receiving area. In this case, the suspension part can be designed like a spring washer or a trampoline suspension. In one embodiment, for example, the suspension part completely surrounds the peripheral area of ​​the receiving area. Similarly, the suspension part can only be arranged in a partial area around the periphery of the receiving area. Thus, the sensor holder can achieve a defined cantilever positioning of the sensor on an element of the vehicle housing. In addition, in one embodiment, the fixing area can be arranged peripherally around the suspension part. In this case, the fixing area can have any desired peripheral geometry.

[0054] The suspension element is preferably positioned close to the receiving area so that forces acting on the sensor can be directly incorporated into the suspension element and absorbed or converted there. The suspension element preferably has a small transverse dimension Q. Preferably, the transverse dimension Q of the suspension element, viewed in a cross-sectional or longitudinal section of the sensor holder, is smaller than the transverse dimension of the receiving area. This ensures that the suspension element is not located within the sensor's transmission angle and therefore does not affect the sensor when receiving or transmitting signals. Therefore, the suspension element is preferably compact and / or lightweight.

[0055] The suspension portion can bring about both a change in length and a change in flexion of the fastening region and thus acts elastically both longitudinally and transversely in the direction of the fastening region.

[0056] In a preferred embodiment, multiple fixing regions may be provided, at least one of which forms at least one tongue, including a suspension portion for connecting the fixing region to the receiving region. Preferably, two or more fixing regions are arranged around the periphery of the receiving region. The fixing regions may be identical or different. At least one fixing region may not have a suspension portion, thereby allowing for a defined positioning of the sensor holder on the attachment element or a non-elastic plug or cable connection. Each fixing region may be designed as a tongue. In this case, the suspension portions are formed in substantially the same manner on the different fixing regions. If multiple tongues are provided, each with at least one suspension portion, the suspension portions are preferably arranged approximately at least at certain locations around the periphery of the receiving region. In this case, the trajectory of the suspension portion does not need to be adjusted to completely coincide with the trajectory of the periphery of the receiving region. This is only advantageous if forces acting on the receiving region can be directly incorporated into the suspension portion, thereby relieving the load on the attachment region. It is conceivable to provide at least two suspension portions in series and / or parallel to each other in each fixing region to make the suspension effect adjustable and adaptable to the respective load. It is also conceivable to adapt the loads by selecting the wall thickness and / or the transverse dimensions.

[0057] In a preferred embodiment, the at least one suspension portion is formed integrally with the at least one fixing region, in particular the tongue, wherein the suspension portion is preferably designed as a solid hinge, in particular as a material embossment and / or a material bend. The suspension portion is preferably formed in a spatial direction X, which is opposite to the sensor direction S, which defines the sensitivity of the sensor. A plane perpendicular to the normal plane formed by the spatial direction X and the sensor direction S preferably forms the plane in which the at least one fixing region is formed and in which the receiving region is located. This ensures that the geometric dimensions of the suspension portion do not affect the movement of the sensor. The suspension portion is preferably formed as a material embossment or a material bend. Because the suspension portion is formed as a solid hinge in the sense of a solid suspension, in particular, formed integrally from the same material as the fixing region, it does not function as a true hinge in the sense of a kinematic joint, but rather operates based on elastostatic (elastic) principles. The suspension function can be achieved by a region having lower flexural stiffness relative to two adjacent regions having higher flexural stiffness. The reduced bending stiffness can preferably be achieved by local cross-section reduction in the form of a film hinge, but can also be achieved in combination or solely by material embossing and / or material bending. It is also conceivable to use parts made of other materials or modified materials with elastic bending properties.

[0058] In a preferred embodiment, the suspension part can have different areas. In this case, one area can be designed to compensate for longitudinal displacement or lateral displacement. Another area can be designed to compensate for rotation. The suspension part preferably has different elasticities in the at least two areas. This can be formed, for example, by combining material embossing or material bending formed in different ways. It is also conceivable that different elasticities are achieved by combining a solid body hinge in the form of a film hinge with a local cross-sectional reduction and a material embossing. In this case, the material embossing can, for example, have a first area, while the film hinge has a second area. In such an embodiment, the material embossing can be designed to compensate for longitudinal or lateral displacement and allow the film hinge to rotate. In contrast to conventional film hinges with extremely thin cross-sectional contractions, in order to implement the suspension part in the form of a solid body hinge in the form of a film hinge, only a slight reduction in cross-section is required, it has collision buffering properties to absorb collisions, and has the property of automatically returning to the initial extended position.

[0059] Preferably, the fastening region can be displaced relative to the receiving region by means of the overhanging portion. This can be achieved, for example, by virtue of the overhanging portion being capable of longitudinal or transverse movement, respectively. The longitudinal or transverse movement of the overhanging portion can preferably be achieved by virtue of the overhanging portion being formed as a material embossing or bending.

[0060] In a preferred embodiment, the overhanging portion can be at least partially formed to have a cross-section that is thinner than the fixing area, with the cross-section in the overhanging portion at least partially having a minimum wall thickness t1 that is smaller than another wall thickness t2 in the overhanging portion. In particular, the wall thicknesses t1 and t2 can be smaller than the minimum wall thickness t3 in another cross-section in the region of the at least one fixing area. Preferably, the fixing area and the overhanging portion are integrally formed as a single component. This component can be, for example, an injection-molded component. In particular, the entire sensor holder can be manufactured as an injection-molded component, particularly as a single-piece component. This allows for the production of a sensor holder free of sharp edges and backdrafts. In the region of the overhanging portion, the material can include at least one material bend or embossing and / or be implemented as a self-reversible film hinge in the sense of a solid hinge, formed by elastic deformability of the material at the location of the overhanging portion. Preferably, the material in the overhanging portion is elastic and self-reversibly bendable at least in a direction approximately perpendicular to the X direction. Advantageously, the material in the overhanging portion protrudes substantially from one side of the tongue plane. Preferably, the suspension portion is formed by material deformation in a direction opposite to the emission direction S of the sensor. Thereby, it can be ensured that the suspension portion does not affect the activity of the sensor.

[0061] The overhanging portion in the fixing area can be formed, for example, with a cross-section that alternates between wall thicknesses t3, t2, t1, t2, and t3. Advantageously, in the fixing area, wall thickness t1 is formed to be smaller than t2, while wall thicknesses t1 and t2 are formed to be smaller than wall thickness t3. In particular, wall thicknesses t1 and t2 are arranged in a generally U-shaped bulge in the overhanging portion, for example in the form of a transverse groove. This allows deformation caused by an impact or similar event to which the sensor is subjected to to be compensated, primarily by deformation in the overhanging portion caused by deformation in the elastic transverse groove region.

[0062] The wall thickness may preferably be between 1.0 mm and 3.0 mm. Thus, a typical wall thickness t3 in the fixing area may be 2.7 mm. In particular, the minimum wall thickness t1 in the area of ​​the overhanging portion may be 1.2 mm. More preferably, the wall thickness t2 may be between 1.5 mm and 2.5 mm, in particular 2 mm. In the case of bending of the material, a radius of between 0.5 mm and 5.0 mm may be formed. This results, for example, in a U-shaped elastic transverse groove element having a thinnest point with a wall thickness t1 in a central area (for example on the axis of symmetry). This U-shaped curved portion may have, for example, an outer radius of curvature of 5 mm, and the transition portion to the straight portion of the fixing area may have an outer radius of curvature of 2.5 mm and an inner radius of curvature of 0.5 mm. In this transition portion, the curvature of the straight portion relative to the starting wall of the U-shaped portion may be 75°.

[0063] In a preferred embodiment, the at least one overhanging portion can extend over the entire width of the at least one fixing area, in particular over the entire width of the tongue. Preferably, the width of the at least one overhanging portion can be relatively small, preferably at least less than one-fifth, in particular one-eighth, of the length of the at least one fixing area. The cross-section Q of the overhanging portion should be selected to be small in order not to unnecessarily affect the dimensions of the sensor holder. If there are multiple tongues, each of which has an overhanging portion, the overhanging portion of each tongue preferably extends over the entire width of the tongue. This ensures that deformations mainly occur in the overhanging portion. The overhanging portion can simultaneously allow changes in the length and angle of the fixing area.

[0064] In a preferred embodiment, the width of the fixing area, in particular the width of the tongue, can be narrowed in the area of ​​the overhanging portion. In other words, the overhanging portion is formed to have a length shorter than the width of the fixing area. This allows for material savings without reducing the fixing surface, in particular the attachment surface, in the fixing area. Therefore, the dimensions of the attachment area can be independent of the dimensions of the overhanging portion.

[0065] In a preferred embodiment, the at least one overhanging portion can be designed to absorb shear forces. The force flow can be influenced in particular by the choice of the wall thickness in the region of the overhanging portion, in particular relative to the wall thickness of the fixing region. Thus, for example, different wall thicknesses t1 and t2 can occur in the region of the overhanging portion, each of which is designed to be smaller than the wall thickness t3 in the region of the fixing region.

[0066] In a preferred embodiment, due to a predetermined load on the sensor inserted into the receiving area, a shear force can act on the sensor holder. In this case, the load can act perpendicularly or at an angle to the front face of the sensor.

[0067] In a preferred embodiment, the receiving region can be integrally formed with the at least one fixing region. In particular, the sensor holder can be manufactured entirely from a single component. Thus, the suspension portion, the fixing region, and the receiving region can be made of the same material. Different functions, in particular load-relieving functions, can thus be achieved by different wall thicknesses or different geometries. In particular, the sensor holder can be made of plastic and manufactured using an injection molding process.

[0068] In a preferred embodiment, the receiving area may include a receiving chamber that is open on at least one side to receive the sensor, with the at least one fixing area arranged on the open side of the receiving chamber, and the overhanging portion forming a positionally reversible and collision-resistant connection between the attachment area and the receiving area. In particular, the receiving chamber cannot overlap with the at least one fixing area in the sensor direction S. Therefore, the sensor can be inserted into the open chamber from one side. Preferably, the receiving area can be open, for example, by a lid and / or hinge in the bottom area of ​​the closed chamber. For example, with the lid open, the sensor can be inserted into the receiving chamber via the open side opened by the lid and retained on the open side by a protrusion and locking structure. To this end, a stopper or similar element is preferably arranged on the open side of the receiving chamber to prevent the sensor from falling out of the receiving chamber through the open side. After the sensor is inserted into the receiving area, the lid can be closed, for example, by snapping, so that the sensor can be retained in the receiving area in an easily replaceable manner. Preferably, the sensor is securely mounted in the receiving area so that it cannot slide within the receiving area. Preferably, the fixing area is arranged on the open side of the receiving chamber, so that the receiving chamber protrudes substantially only from one side relative to the plane of the fixing area. This ensures that the sensor can be positioned as close as possible to the inner surface of the vehicle shell, while still maintaining a certain distance therefrom. In particular, the sensor can thus be positioned very close to the inner surface of the bumper. This is particularly important for achieving a compact, space-saving arrangement and precise alignment without affecting the sensor's movement.

[0069] In a preferred embodiment, the receiving area can have a substantially basin-shaped shape, and the at least one fastening area can be connected to the receiving area in the area of ​​its upper edge. This also ensures that the sensor is arranged as close as possible to the inner surface of the vehicle housing.

[0070] In a preferred embodiment, the attachment area can be formed as a raised surface in the fixing area. In this case, the raised surface can be formed as a welding surface, in particular a welding disk, for attaching to the surface of the additional element (for example, by plastic welding to the inner surface of the bumper). In other words, the raised surface is then used as a welding surface. By means of the overhanging part, the receiving area can be mounted to be collision-resistant and positionally reversible relative to the attachment area. The attachment area is preferably designed to be raised relative to the fixing area, the raising being raised from the fixing area on the side opposite to the material embossing or material bending intended to form the overhanging part. Therefore, the space available for forming the overhanging part is not affected by the height of the attachment area. On the contrary, the overhanging part can be formed arbitrarily, for example in the direction of a receiving cavity open on one side or in the direction of a basin-shaped receiving area.

[0071] In a preferred embodiment, at least three, in particular four, fixing areas may be included. At least two, in particular three, of the fixing areas may have overhanging portions that are arranged at a distance from the receiving area so as not to affect the movement of the sensor. Preferably, at least one fixing area may not include any overhanging portions. Thus, in an embodiment having a total of four fixing areas, for example, three fixing areas may each have at least one overhanging portion, while one fixing area may not have any overhanging portions. Preferably, the fixing areas are evenly arranged around the receiving area so that forces can be evenly dissipated over the entire circumference of the receiving area. In this case, for example, the fixing areas may include an attachment via a cable or via a plug, which is advantageously formed in a non-elastic and / or non-overhanging manner to avoid breakage of the cable or disconnection of the attachment via the plug during the service life. This makes it possible, in particular, to ensure that the maximum permissible tolerance of less than 3° for sensor deviation is adhered to.

[0072] In a preferred embodiment, the sensor bracket can be constructed from a glass-fiber-filled elastomer, particularly an elastomer based on PP / EPDM (polypropylene / ethylene-propylene-diene monomer), preferably with a glass fiber content of at least 5%. Specifically, the sensor bracket can be constructed from PP GF5 (polypropylene filled with 5.0% glass fiber reinforcement). This material can absorb radiation from the sensor and provide significant rigidity for sensor orientation. Preferably, the sensor bracket can be substantially stiffer than the additional component to which it is attached, particularly the bumper. In particular, the glass fiber filling allows the sensor bracket to be stiffer than the component to which it is attached. For example, the sensor bracket can thus be stiffer than the bumper. In particular, the different elastic properties between the bumper and the sensor bracket can result in high shear forces in the attachment area within the attachment area. The at least one overhanging portion can absorb these shear forces, thereby relieving the attachment area. This can, for example, prevent the sensor bracket from becoming loose from the bumper during the aforementioned crash test.

[0073] In a preferred embodiment, the sensor holder can be manufactured using an injection molding process. This makes the shape of the sensor holder easy to implement. This allows for various geometries of the suspension part to be implemented. During the injection molding process, the sensor holder can be equipped with additional elements designed, for example, to optimize transmission and reception performance and prevent unwanted radar reflections from the sensor holder.

[0074] The present invention also relates to an assembly in which the sensor bracket is arranged on a bumper. In addition, it is conceivable that the sensor bracket can also be arranged on other inner surfaces of components of the vehicle shell.

[0075] It is proposed that the sensor holder be fixed, in particular welded, to the inner surface of the bumper at at least one attachment area. The sensor is received in the sensor holder and arranged between the inner surface of the bumper and the sensor holder. The sensor is fixed in a crash-resistant manner by means of a suspension portion and is reversible relative to the inner surface of the bumper. For example, sensors for driver assistance systems, such as medium-range radar sensors (MRR sensors), can be arranged in this position. The same advantages and designs as described above for the sensor holder also apply to the assembly in which the sensor holder is arranged on the bumper.

[0076] The described sensor bracket and the assembly consisting of the described arrangement of the sensor bracket on the bumper allow the sensor to be positioned on the inner surface of the vehicle's exterior. On the one hand, the sensor bracket has sufficient rigidity to align the sensor in the desired position relative to the vehicle's longitudinal axis. On the other hand, the positioning is designed to be sufficiently resilient to prevent the sensor bracket from being dislodged from the inner surface in the event of an impact on the sensor. BRIEF DESCRIPTION OF THE DRAWINGS

[0077] Further advantages emerge from the drawings and the following description of the drawings. The drawings illustrate embodiments of the present invention. The drawings, the description, and the claims contain many combined features. Those skilled in the art will also appropriately consider these features individually and combine them into meaningful, complementary combinations.

[0078] The invention will be better understood from reading the following description, which is given by way of example only and with reference to the accompanying drawings, in which:

[0079] - Figure 1 An embodiment of a sensor support according to the present invention is shown in plan view;

[0080] - Figure 2 Shown from the opposite side Figure 1 A plan view of an embodiment of the invention;

[0081] - Figure 3 Shown Figure 1 Another perspective view of an embodiment of the invention;

[0082] - Figure 4 Shown Figure 1 Another perspective view of an embodiment of the invention;

[0083] - Figure 5One embodiment of the suspension portion is shown in cross-section;

[0084] - Figure 6 An embodiment of the arrangement of the sensor bracket on the inner surface of the bumper is shown in a cross-sectional view;

[0085] - Figure 7 A schematic plan view of another embodiment of a sensor holder according to the invention is shown. DETAILED DESCRIPTION

[0086] In the drawings, the same or similar components are denoted by the same reference numerals.

[0087] Figure 1 An embodiment of a sensor holder 10 is shown in plan view. The sensor holder 10 has a central receiving area 14, which can accommodate at least one sensor 16, for example, sensor 16, or in another example, multiple sensors. Four tongues 24 are arranged around the periphery of the receiving area 14. Each of these tongues 24 forms a fixing area 18. The fixing areas 18 have different geometric shapes. Each fixing area 18 has an attachment area 20, which in this embodiment has a substantially rectangular geometry. In this embodiment, the geometry of the attachment area 20 is independent of the geometry of the tongues 24 or the fixing areas 18. Three of the four fixing areas 18 have overhanging portions 22. In each case, a overhanging portion 22 is provided on a corresponding tongue 24. Each overhanging portion 22 is located between the attachment area 20 and the receiving area 14. Since a plug-in connection for the sensor is provided in this embodiment, the tongue 24 on the right side of the figure does not have any overhanging portion 22. Preferably, the fixing area 18 does not have elastic properties to prevent cable breakage or plug detachment. In another embodiment (not shown), a suspension portion 22 can also be provided on tongue 24. Despite the suspension portion 22, sufficient rigidity can be achieved at the tongue. Furthermore, this ensures that sensor holder 10 can securely attach sensor 16 to a desired location, such as on the inner surface of a bumper (not shown). If suspension portion 22 were also provided on tongue 24, the position of sensor 16 relative to the bumper would be uncertain. In contrast, tongue 24 has a structured surface 28 that prevents radar reflections in the area of ​​sensor holder 10. The attachment area 20 and suspension portion 22 are sufficiently far from sensor 16 so as not to affect the active surface of sensors such as the sonotrode or the antenna of sensor 16. Consequently, the movement of the sensor is unaffected by sensor holder 10.

[0088] exist Figure 2 Shown in Figure 1 The figure shows the sensor bracket 10 relative to Figure 1 In this case, it can be seen that the receiving area 14 is formed as a receiving chamber 32. Figure 1 The open side 34 of the receiving chamber 32 can be seen in FIG. Figure 2 A cover 38 is shown in the lower region of the receiving chamber 32. The cover 38 can be opened so that the sensor 16 can be inserted from the bottom side of the receiving chamber 32 into the receiving area 14. On the open side 34, a projection 40 is arranged on the receiving chamber 32 so that the sensor 16 is clamped in the receiving chamber 32 on the open side 34. After closing the cover 38, the sensor 16 is fixed immovably in the receiving area 14 and aligned in position.

[0089] Figure 3 Shown Figure 1 Another view of the sensor holder 10 of an embodiment of the present invention. In this case, the sensor holder 10 is shown without the sensor 16 inserted. In the perspective view, it can be seen that the attachment area 20 is formed as a raised surface area in the fixing area 18. When considered in this view, the attachment area 20 is formed so as to be raised upwards relative to the plane of the fixing area 18. On the other hand, the receiving area 14 is designed as a receiving cavity 32 that protrudes on the side opposite to the plane of the fixing area 18. This ensures that the sensor holder 10 can be mounted as close to an inner surface as possible with the attachment area 20, so that the movement of the sensor is not affected by the inner surface (for example, the inner surface of the bumper). By protruding from the receiving cavity 32 in the opposite direction, any larger sensor can be accommodated in the sensor holder 10, because the size of the sensor 16 does not affect the distance of the sensor 16 from the inner surface.

[0090] Figure 4 Shown Figure 1 Another perspective view of an embodiment of the present invention is shown. Sensor 16 is not shown in this illustration. It can be seen that fixing region 18 lies in the curved plane relative to receiving region 14. This allows sensor holder 10 to be adapted to different inner surfaces of a component. This ensures that, for inner surfaces with varying curvatures, sensor 16 can be positioned as close as possible or as close as necessary.

[0091] A cross section of a possible embodiment of the suspension portion 22 is Figure 5. The suspension portion 22 is shown here as a material embossing 26 or a material bend. The suspension portion 22 is partially formed to have a thinned cross-section. The wall thickness t1 of the suspension portion 22 in the central area is less than the wall thickness t2 in the side areas of the suspension portion 22. Both of these wall thicknesses t1 and t2 are less than the wall thickness t3 of the cross-section in the area of ​​the fixing area 18. In particular, the area covering the width Q can be used as the suspension portion 22 because the area is designed to be more elastic than the adjacent parts of the fixing area. This allows a relative displacement between the receiving area 14 and the fixing area 18. Such a suspension portion 22 can, for example, allow the suspension portion 22 itself to undergo longitudinal or lateral displacement because the suspension portion has the thinnest cross-section in the upper central area.

[0092] It is also conceivable to form a film hinge in the form of a solid hinge by forming the wall thickness t1 greater than the wall thickness t2. Such a film hinge (not shown) allows for angular rotation in the hanging part 22. This allows for rotation between the fixing area 18 and the receiving area 14.

[0093] It is further conceivable to arrange a plurality of material embossments 26, shown as being arranged adjacent to one another in series or parallel to one another, to form a continuous suspension portion 22 with adjustable suspension properties. In another embodiment, material embossments and film hinges in the sense of solid body hinges can be combined or arranged adjacent to one another. Thus, a combination of at least longitudinal or transverse displacement and angular rotation can be achieved.

[0094] Additionally, the depending portion 22 may have a different cross-sectional geometry than the illustrated embodiment.

[0095] exist Figure 6 FIGURE 2 shows the arrangement of sensor bracket 10 on bumper 12. Sensor bracket 10 is arranged in a side region of bumper 12. Sensor bracket 10 is secured to inner surface 36 of the bumper via attachment region 20. Receiving region 14 has a protrusion 40 (not visible in this illustration) on open side 34. In conjunction with cover 38, sensor 16 can thus be held securely in receiving region 14.

[0096] Figure 7The diagram shows a sensor holder 10 having a fixing area 18. The fixing area 18 is formed continuously around the periphery of the receiving area 14. Within the fixing area 18, a plurality of attachment areas 20 are arranged. These areas are regularly distributed around the receiving area 14. The attachment areas 20 serve for fixing to the additional element. In this case, fixing can preferably be achieved by welding or a combination of welding and rivet welding. However, other types of fixing are also possible. Thus, the sensor holder 10 can be screwed, glued, riveted, or even clamped to the inner surface of the additional element via the attachment areas 20, for example. A suspension portion 22 is provided between the attachment area 20 and the receiving area 14. The suspension portion 22 extends over almost the entire periphery of the receiving area 14. In this case, the suspension portion 22 does not need to follow the peripheral geometry of the receiving area 14. Instead, the suspension portion 22 can have any desired geometry or trajectory. It is also conceivable that the suspension portion 22 is formed as a continuous peripheral structure. If the sensor 16 (not shown) arranged in the receiving area 14 moves due to an external impact, the resulting forces can be absorbed and compensated by the suspension portion 22. This particularly reduces the strain on the attachment area 20. This prevents the sensor holder 10 from falling off the inner surface of the attached component (e.g., a bumper). Typically, by means of an elastic suspension portion 22, such as a U-shaped elastic element, the sensor holder 10 can be provided with a sufficiently rigid structure to allow the sensor 16 to be fixed as securely as possible. This allows for precise positioning of the sensor 16, ensuring a deviation of less than 3° over its service life. Furthermore, the suspension portion 22 makes the sensor holder 10 so resilient that forces generated, for example, by impact loads, are adequately compensated and absorbed within the suspension portion 22. In particular, even if no other supporting structure is arranged behind the sensor 16 and the sensor 16 is arranged to be almost freely suspended, the sensor holder 10 can be prevented from falling off the inner surface of the attached component.

[0097] List of reference numerals:

[0098] 10: Sensor bracket

[0099] 12: Bumper

[0100] 14: Receiving area

[0101] 16: Sensor

[0102] 18: Fixed area

[0103] 20: Attachment area

[0104] 22: Suspension part

[0105] 24: Tongue

[0106] 26: Material embossing

[0107] 28: Structured Surface

[0108] 30: Upper edge area

[0109] 32: Receiving chamber

[0110] 34: Open side

[0111] 36: Inner surface of bumper

[0112] 38: Cover

[0113] 40: protrusion

[0114] B: Width

[0115] L: length

[0116] Q: Width of the suspension part

[0117] t1: Wall thickness of the central area of ​​the suspension part

[0118] t2: Wall thickness of the side area of ​​the suspension part

[0119] t3: Wall thickness of fixed area

[0120] X: spatial direction

[0121] S: sensor direction.

Claims

1. A sensor bracket (10) for a vehicle, comprising at least one receiving area (14) for accommodating a sensor (16) and at least one fixing area (18), wherein the sensor bracket (10) can be fixed to an additional element via the fixing area, and wherein at least a portion of the at least one fixing area (18) comprises an attachment area (20) for attaching the additional element by fixing. The sensor holder (10) is constructed such that at least one elastic suspension portion (22) is arranged on at least one fixing region (18) between the attachment region (20) and the receiving region (14). It is characterized in that The attachment area (20) is designed as a raised surface in the fixing area (18), which is processed in the form of a welding surface, And the sensor bracket (10) is suitable for being manufactured by an injection molding process.

2. The sensor bracket (10) for a vehicle according to claim 1, characterized in that The sensor bracket (10) is used for being arranged behind a bumper (12) of a vehicle and can be fixed to the bumper (12) via the at least one fixing area (18).

3. The sensor bracket (10) for a vehicle according to claim 1, characterized in that The raised surface is machined in the form of a welding pad.

4. The sensor bracket (10) for a vehicle according to claim 1, characterized in that A plurality of fixing areas (18) are provided, wherein at least one fixing area (18) forms at least one tongue (24) comprising the elastic hanging portion (22) for connecting the attachment area (20) to the receiving area (14).

5. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The at least one elastic suspension portion (22) and the at least one fixing area (18) are formed as a single piece.

6. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The elastic suspension part (22) has different areas, one area is designed to compensate for longitudinal displacement and lateral displacement respectively, and the other area is designed to compensate for rotation.

7. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The elastic suspended portion (22) is at least partially formed to have a thinned cross-section having at least partially a first wall thickness (t1) that is less than a second wall thickness (t2) in the elastic suspended portion (22).

8. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The at least one elastic suspension portion (22) extends over the entire width (B) of the at least one fixing region (18).

9. The sensor bracket (10) for a vehicle according to claim 8, characterized in that The at least one elastic suspension portion (22) has a width (Q) that is smaller than a length (L) of the at least one fixing region (18).

10. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The width (B) of the fixing region (18) is formed to be narrowed in the region of the elastic suspension portion (22).

11. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The at least one elastic suspension portion (22) is designed to absorb shear forces.

12. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The receiving area (14) is formed integrally with the at least one fixing area (18).

13. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The receiving area (14) comprises a receiving cavity (32) which is open on at least one side, the at least one fixing area (18) is arranged on the open side (34) of the receiving cavity (32) and forms a connection between the attachment area (20) and the receiving area (20) via the elastic hanging portion (22), and the receiving cavity (32) does not overlap with the at least one fixing area (18).

14. The sensor bracket (10) for a vehicle according to claim 13, characterized in that In the sensor direction (S), the receiving chamber (32) does not overlap with the at least one fastening area (18).

15. The sensor bracket (10) for a vehicle according to claim 13, characterized in that The receiving area (14) has a pot-like shape, and the at least one fastening area (18) is connected to the receiving area in an upper edge area (30) of the receiving area (14).

16. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The sensor bracket comprises at least three fixing areas (18), wherein at least two fixing areas (18) have elastic suspension parts (22), and the elastic suspension parts (22) are arranged away from the receiving area (14) so ​​as not to affect the activity of the sensor.

17. The sensor bracket (10) for a vehicle according to any one of claims 1 to 4, characterized in that: The sensor bracket (10) is composed of an elastomer loaded with glass fiber.

18. The sensor bracket (10) for a vehicle according to claim 17, characterized in that The elastomer has a glass fiber content of at least 5%.

19. An assembly comprising a sensor bracket (10) for a vehicle according to any one of the preceding claims and arranged on a bumper (12), characterized in that: The sensor bracket (10) is welded to the bumper inner surface (36) at the attachment area (20), and the sensor (16) is accommodated in the sensor bracket (10) and arranged between the bumper inner surface (36) and the sensor bracket (10), and is fixed relative to the bumper inner surface (36) by an elastic suspension portion (22).

Images