Protection element for a vehicle sensor for radiation emission or reception and related method

Abstract

A protective element (1) for a radiation emission or reception sensor (2), the radiation emission or reception sensor (2) being mounted on a vehicle body part (3), such as a radar or a camera, the protective element comprising a support (4) configured to be fixed to the vehicle body part in front of the sensor; wherein the support (4) is made entirely of a transparent synthetic plastic material or a material permeable to light radiation or radio frequency, and a first face (9) of the support facing the sensor is lined with a transparent film (6) defined by a first face (7) and a second face (8) opposite the first face, the first face (7) of the transparent film facing the support and being fixed so as to adhere to the support and be integral with the support, and the second face (8) being provided with a continuous or discontinuous decorative layer (11); at least a part (12) of the first face of the transparent film that faces the sensor in use is provided with a resistor (13) integrally formed thereon.

Description

[0001] Cross - reference to related applications

[0002] This patent application claims the priority of Italian Patent Application No. 102019000025396, filed on December 23, 2019, the entire disclosure of which is incorporated herein by reference. Technical field

[0003] The present invention relates to a protective element for a radiation - emitting or receiving sensor, which is mounted on a vehicle, such as a radar or camera mounted on a front or rear body part, typically but not exclusively on a bumper. The protective element involved in the present invention is called a "radome" in technical terms, which is an abbreviation from the English words "radar" and "dome". The present invention also relates to a related method. Background art

[0004] Modern vehicles are increasingly equipped with sensors that emit or receive optical radiation or radio - frequency radiation, such as cameras or radars.

[0005] These sensors, which are usually mounted on or behind the bumper, typically front sensors, on the one hand, must be protected against accidental collisions and direct splashes of external contaminants (e.g., water or mud), and on the other hand, their operating functions must be protected from being hindered.

[0006] Currently, these conflicting requirements have not been fully met because the protection of the sensors has been entrusted to other body elements, such as protective grilles or frames. Moreover, even when sufficient protection is obtained in cases where only partially impairs the efficiency of the sensors, the sensors are still exposed to cold, so in winter, the sensors and / or the protective elements may freeze, which can change the function of the sensors or make them inoperative. Summary of the invention

[0007] An object of the present invention is to provide a protective element and a related method for protecting a radiation - emitting or receiving sensor without the drawbacks of the prior art, the radiation - emitting or receiving sensor being mounted in a vehicle, such as a radar or camera mounted on a front or rear body part such as a bumper. The element and method can effectively protect the sensor without changing or hindering its function even in winter and in icing conditions, while being easy to produce and install, and can form a protective element that is fully integrated with the aesthetic appearance of the vehicle on which it is mounted.

[0008] Accordingly, according to the present invention, there is provided a protection element for a radiation emission or reception sensor and a related method, the emission or reception sensor being mounted in a vehicle, such as a radar or camera mounted on a body part at the front or rear, typically but not exclusively on a bumper, wherein a support member configured to be fixed to the body part in front of the emission or reception sensor is made entirely of a transparent synthetic plastic material or a material capable of transmitting light radiation or radio frequency, and includes a transparent film defined by a first face and a second face opposite the first face, the transparent film being fixed integrally entirely to the first face of the support member facing the emission or reception sensor in use; and wherein the first face of the transparent film facing the first face of the support member is arranged to adhere in contact with the first face of the support member, while the second face of the transparent film is at least partially lined with a decorative layer applied thereto in a permanent manner; at least one first portion of the first face of the transparent film is provided with a resistor formed integrally thereon, the first portion being configured to be arranged to face the emission or reception sensor in use. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Other features and advantages of the present invention will become more apparent from the following description of non-limiting embodiments of the present invention provided with reference to the accompanying drawings, in which:

[0010] - Figure 1 A three-quarter front perspective view in exploded form of a protection element for a vehicle sensor manufactured according to the present invention is schematically shown, with details also shown in an enlarged cross-section; and

[0011] - Figure 2 A method for manufacturing the Figure 1 protection element in DETAILED DESCRIPTION

[0012] With reference to Figure 1 , herein reference numeral 1 denotes a protection element for a radiation emission or reception sensor 2 mounted on a vehicle, such as a radar or camera schematically shown only in dashed lines (likewise for sensor 2) mounted on a body part 3 at the front or rear. The vehicle can be of any kind and is not shown for simplicity.

[0013] The protection element 1 includes a support member 4 configured to be fixed to the body part 3 in front of the radiation emission or reception sensor 2.

[0014] To this end, the support member 4 includes a series of fastening elements or means 5 known and only schematically shown, which generally include quick-release tabs or hooks and / or holes, wings or lugs for receiving fastening screws, which are not shown for simplicity.

[0015] According to a first aspect of the invention, the support member 4 is made entirely of a transparent synthetic plastic material or, in any case, of a material that is permeable to light radiation (e.g., light) or to radio frequencies such as radar waves. As will be seen, the support member 4 is made of a synthetic plastic material by injection molding or compression molding, which synthetic plastic material is preferably rigid but still has a certain elasticity, such as polycarbonate, polyethylene, plexiglass, etc.

[0016] The protection element 1 further includes a transparent film 6 defined by a first face 7 and a second face 8 opposite the first face 7.

[0017] According to one aspect of the invention, the transparent film 6 is integrally fixed to the first face 9 of the support member 4 that faces the transmitting or receiving sensor 2 in use (i.e., facing the interior of the vehicle).

[0018] Compared with the vehicle body part or element 3, the face 9 is the inner face of the support member 4, which is preferably cup-shaped or semi-shell-shaped to give it a certain structural stiffness.

[0019] On the contrary, the first face 7 of the transparent film 6 faces the support member 4 and thus faces the outside of the vehicle, and is on the side opposite to the sensor 2 and the vehicle body part or element 3 in use.

[0020] In addition, the face 7 is arranged to be attached in contact with the first face 9 of the support member, and the face 7 is arranged parallel to the first face 9, covering the first face 9 and replicating its shape.

[0021] Both the support member 4 and the transparent film 6 can be provided with holes and other maintenance openings and can thus be continuous or discontinuous. In the non-limiting example shown, the support member 4 has through holes or windows 10 arranged away from the sensor 2.

[0022] According to one aspect of the invention, the second face 8 of the transparent film 6 is at least partially lined with a decorative layer 11, which is permanently applied to the face 8 so that it adheres to the face.

[0023] In addition, according to another aspect of the invention, at least one first portion 12 of the first face 7 of the transparent film 6 that always remains free of the decorative layer 11 is configured to face the transmitting or receiving sensor 2 in use and is provided with a resistor 13 formed on the face 7, which resistor is integrally rigid with the face 7 and corresponds to its portion 12.

[0024] The decorative layer 11 is applied to the second face 8 of the transparent film 6 in a continuous or discontinuous manner, i.e., the decorative layer 11 can line all or only a part of the face 8, for example leaving some selected parts of it uncovered.

[0025] The decorative layer 11 applied to the second face 8 of the transparent film 6 is generally monochromatic and is preferably configured to match the body part 3 on which the protection element 1 (referred to as a radome in technical terms) is intended to be joined.

[0026] According to a possible variant, the decorative layer 11 applied to the second face 8 of the transparent film 6 is multicolored and / or includes graphics, text, or logos made to be readable through the face 7 and thus also through the support 4.

[0027] The second face 8 of the transparent film 6 is also provided, near a first part 12 of the first face 7 of the transparent film 6, with at least one electrical connection element 14 of a known type, which is electrically and mechanically connected to the resistor 13 by means of at least one shunt 15 passing through the transparent film 6.

[0028] At least one electrical connection element 14 is integrally fixed to the second face 8 of the transparent film 6 on the resistor 13 side and thus on the lateral side of the part 12 of the face 8 by gluing or ultrasonic welding or any other suitable technique or procedure (even using screws or rivets if necessary).

[0029] At least one electrical connection element 14 can be integrally fixed to the second face 8 of the transparent film 6 either directly (thus on the area of this second face 8 without the decorative layer 11) or preferably by being inserted into the decorative layer 11. In both cases, the decorative layer 11 is formed before installing the electrical connection element 14, finally leaving the area of the face 8 for receiving the electrical connection element 14 uncovered.

[0030] The resistor 13 extends in a continuous or discontinuous manner so as to cover all or part of the part 12 of the first face 7 of the transparent film 6, and the resistor 13 is selected from the group consisting of: a filament 16 ( Figure 1 , enlarged rectangle), which is made of a metal conductor directly deposited on the first face 7 of the transparent film 6 according to a grid or comb pattern in the shape of a snake (shown in a non - limiting way) or according to other patterns or arrangements considered suitable, the metal conductor being preferably copper or its alloy; a continuous or discontinuous ITO layer (indium tin oxide, known to be transparent); or a combination thereof. Any other type of resistor is also suitable for this purpose, as long as it maintains its light or radio - frequency transmissibility on a part of the part 12 of the face 7 that is in front of the sensor 2 during use.

[0031] According to what has been described above and with reference to Figure 2, it is also clear that the present invention relates to a method for protecting a radiation emitting or receiving sensor 2, which is mounted on a vehicle, such as a radar or camera mounted at a body part 3 at the front or rear. The method includes the following steps:

[0032] First step: Produce a sheet-like or strip-like transparent film 6 from a synthetic plastic material, preferably polycarbonate, in a known manner. The transparent film 6 preferably has a thickness between 0.2 and 0.4 mm to have high flexibility and deformability.

[0033] Second step: Apply a resistor 13 on at least a first part 12 of the first face 7 of the transparent film by metal deposition, screen printing or glue, so that the resistor 13 becomes an integral part of the transparent film 6.

[0034] Third step: Apply a continuous or discontinuous decorative layer 11 on the second surface 8 of the transparent film 6. The decorative layer 11 is monochromatic or multicolored and has any text or logo that can be read through the transparent film 6. This third step is performed before or after the second step, but always without covering the part 12 with the decorative layer 11 because this part 12 must remain transparent.

[0035] It should be noted that the numerical adjectives "first", "second", etc. used here should not be understood as indicating a time or functional sequence, but should simply be understood as concisely distinguishing the attributes of each step.

[0036] Fourth step: Preform the transparent film 6 in a first mold 18 ( Figure 2 a) by heating (thermoforming) for example to eliminate unnecessary peripheral parts 19. At this time, the film 6 is usually no longer completely transparent because it has received the decorative layer 11 on its face 8.

[0037] During this thermoforming step ( Figure 2 b), in which at least a partial network of the polymer used to make the film 6 is obtained, the film 6 is given a final predetermined shape configured to be continuously coupled to the front or rear body part 3, such as a profile and a cup shape ( Figure 2 b). In this step, the film 6 also acquires a certain stiffness and its own shape.

[0038] Fifth step: Co-mold a support 4 made of a transparent synthetic plastic material or in any case a material that can transmit light radiation or radio frequency on the first face 7 of the transparent film 6 in a second mold 20 ( Figure 2 c) so that the support 4 has a shape matching the shape of the preformed transparent film 6 and form fastening elements for the vehicle, such as the elements or devices 5 already described, on the support 4. At the end of this step ( Figure 2d), an almost completed protective element 1 is obtained.

[0039] In a sixth step (not shown) which is to be carried out before and / or after the preforming and / or co-forming steps, at least one electrical connection element 14 for the resistor 13 is integrally fixed to the second face 8 of the transparent film 6. The connection element is electrically and mechanically connected to the resistor by means of a shunt 15 passing through the transparent film 6.

[0040] Finally, in a seventh and final step, the thus obtained protective element 1 is integrally assembled with the vehicle body part 3 by means of the element 5. The transparent part 12 is arranged in front of / facing the sensor 2, and the sensor 2 is arranged at a pre-fixed and relatively small distance from the transparent part 12.

[0041] In this seventh step, the protective element 1 is applied such that it extends over the entire length of the vehicle body part 3 and forms a stylistic and functional extension thereof without interruption of continuity.

[0042] Finally, it is clear from the description that the present invention also extends to vehicles (known and not shown) comprising the described protective element 1 for the radiation emitting or receiving sensor 2. The protective element 1 is preferably applied over the entire length measured in a direction perpendicular to the vehicle of the front or rear bumper 3.

[0043] Due to the described structure, the manufacture and assembly of the protective element 1 are easy and economical at the position facing the sensor 2 to be protected. It provides comprehensive protection for the sensor 2 because it acts as a screen for the sensor, but at the same time does not hinder its operation because, for this purpose, the part 12 of the face 7 is large enough. Finally, even in cold weather with a risk of icing, it does not cover the part 12 of the face 7 and thus hinder the operation of the sensor 2 because the ice is rapidly melted (or even prevented from forming) by the resistor 13.

[0044] Thus, all the objects of the present invention are achieved.

Claims

1. A protective element (1) for a radiation emission or reception sensor (2), said radiation emission or reception sensor (2) being mounted at a body part (3) at the front or rear of a vehicle, said protective element comprising a support (4) configured to be fixed to the body part (3) in front of the emission or reception sensor (2); wherein the following features are combined: i) - The support (4) is made entirely of a transparent synthetic plastic material or a material that is permeable to light radiation or radio frequency; ii) - The protective element further comprises a transparent film (6) defined by a first face (7) and a second face (8) opposite the first face, said transparent film (6) being fixed integrally entirely to the first face (9) of the support (4) that faces the emission or reception sensor (2) in use; iii) - The first face (7) of the transparent film (6) faces the support (4) and is arranged to be attached in contact with the first face (9) of the support; iv) - The second face (8) of the transparent film is at least partially lined with a decorative layer (11) applied thereto in a permanent manner; and v) - At least one first portion (12) of the first face (7) of the transparent film (6) is provided with a resistor (13) formed integrally entirely thereon, said first portion (12) being configured to be arranged to face the emission or reception sensor (2) in use; characterized in that, vi) - The second face (8) of the transparent film is provided with at least one electrical connection element (14) at the first portion (12) of the first face (7) of the transparent film, said electrical connection element being electrically and mechanically connected to the resistor (13) by means of at least one shunt (15) passing through the transparent film; vii) - The at least one electrical connection element (14) is integrally fixed on the second face (8) of the transparent film by being inserted into the decorative layer (11).

2. The protection element according to claim 1, wherein The decorative layer (11) is applied to the second face (8) of the transparent film in a continuous or discontinuous manner.

3. The protection element according to claim 1, characterized in that, The decorative layer (11) applied to the second face of the transparent film is monochromatic and is configured to match the color of the body part (3).

4. The protection element according to claim 1, characterized in that, The decorative layer (11) applied to the second face of the transparent film is multicolored and / or includes patterns, letters or logos.

5. The protection element according to claim 1, characterized in that, The at least one electrical connection element (14) is integrally fixed on the second face (8) of the transparent film on one side of the resistor (13) by gluing or ultrasonic welding or another suitable process.

6. The protection element according to claim 1, characterized in that, The resistor (13) extends to cover all or part of the first portion (12) of the first face (7) of the transparent film, the resistor (13) being selected from the group consisting of: a filament (16) made of a metal conductor directly deposited on the first face of the transparent film according to a serpentine grid or comb pattern; a continuous or discontinuous ITO layer; a combination thereof.

7. The protection element according to claim 1, characterized in that, The radiation emission or reception sensor (2) is a radar or a camera mounted at the body part (3) at the front or rear.

8. The protection element according to claim 6, characterized in that, The metal conductor is copper or its alloy.

9. A method for protecting a radiation-emitting or receiving sensor (2), the radiation-emitting or receiving sensor (2) being mounted at a body part (3) at the front or rear of a vehicle, characterized in that, The method includes the following steps: a) - Producing a sheet-like or mesh-like transparent film (6) made of a synthetic plastic material; b) - Applying a resistor (13) on at least a first portion (12) of a first face (7) of the transparent film by metal deposition or screen printing or glue, such that the resistor becomes an integral part of the transparent film; c) - Applying a continuous or discontinuous monochromatic or multicolored decorative layer (11) on a second face (8) of the transparent film, the decorative layer having possible text or logo that can be read through the transparent film; d) - Preforming the transparent film (6) in a first mold (18) to eliminate its unnecessary peripheral portion (19) and give it a preset shape, the preset shape being configured to be continuously coupled with the front or rear body part; e) - Co-molding a support (4) made of a transparent synthetic plastic material or a material that can transmit light radiation or radio frequency on the first face (7) of the transparent film, so that the support (4) has a shape matching the shape of the preformed transparent film (6), and making fastening elements (5) to the vehicle on the support (4); f) - Before or after the preforming and / or co-molding steps, integrally fixing at least one electrical connection element (14) of the resistor to a second face (8) of the transparent film (6), the electrical connection element being electrically and mechanically connected to the resistor; g) - Integrally assembling the thus obtained protection element (1) on its body part (3), so that the transparent first portion (12) is arranged in front of / facing the sensor (2); h) - During step f), integrally fixing the at least one electrical connection element (14) on the second face (8) of the transparent film by inserting it into the decorative layer (11).

10. The method according to claim 9, wherein The synthetic plastic material is polycarbonate.

11. The method according to claim 9, wherein The radiation emission or reception sensor (2) is a radar or a camera installed at the front or rear body part (3).

12. A vehicle, which includes a protection element (1) for a radiation emission or reception sensor (2) according to claim 1, the protection element being applied over the entire length measured in a direction transverse to the vehicle on the front or rear bumper.

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