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

Abstract

The invention relates to a sensor assembly for a motor vehicle, comprising at least one sensor element (20) which emits and / or detects electromagnetic radiation in at least one measurement direction in order to determine a measurement signal, a cover element (18) which is arranged in front of the sensor element (20) in the at least one measurement direction, the cover element being an injection-molded plastic part which is at least partially transparent to electromagnetic radiation, and a heating device which comprises a plurality of conductor tracks (34) applied to a backing film (32), the backing film being molded to the cover element (18), the backing film comprising the conductor tracks thereby forming an insert of the injection-molded cover element (18), the conductor tracks being at least partially located on the side of the backing film (32) facing the sensor element. The conductor tracks are electrically conductively connected to one another by at least two bus bars (38), the at least two bus bars (38) each at least partially forming an electrical connection element which protrudes from the cover element (18) and is exposed in order to enable an electrical contact.

Description

Technical Field

[0001] This invention relates to a sensor assembly for a motor vehicle having the features described in the preamble of claim 1. Furthermore, the invention relates to a top module having at least one such sensor assembly, and a motor vehicle having at least one such top module disposed thereon. Additionally, the invention relates to a method for producing a cover element for a sensor assembly for a motor vehicle. Background Technology

[0002] Such sensor assemblies are known in practice for use in motor vehicles to monitor the vehicle environment. To this end, the sensor assembly includes a sensor element that emits electromagnetic radiation in one or more specific directions, such as in the form of laser radiation, so that the vehicle's systems can detect and process the vehicle environment, including road direction, traffic conditions, etc. For example, the sensor element is disposed in the top or front area of ​​the vehicle and behind a cover element that is permeable to the electromagnetic radiation emitted by the sensor element. This cover element can be made of plastic. A heating device can be provided to maintain the permeability of the cover element to electromagnetic radiation even in adverse weather conditions and to de-ice it; this heating device includes a conductive channel disposed inside the cover element, facing the sensor element. For example, this type of sensor assembly is known in DE102018109884A1 and WO2021 / 032599A1.

[0003] Top modules are widely used in vehicle manufacturing because they are prefabricated as independent functional modules and can be sent to the assembly line during vehicle assembly. On its outer surface, the top module at least partially forms the top face of the vehicle, preventing moisture and airflow from entering the vehicle interior. The top skin consists of one or more panel components, which can be made of stable materials, such as painted metal or painted or colored plastic. The top module can be part of a rigid vehicle top or part of an openable top subassembly.

[0004] Furthermore, vehicle manufacturing is increasingly focused on autonomous and semi-autonomous driving. To enable vehicle controllers to operate vehicles autonomously or semi-autonomously, multiple sensor elements are employed, particularly environmental sensors (such as lidar sensors, radar sensors, (multiple) cameras, and sensors including other (electrical) components). These are integrated into a top module to detect the environment surrounding the vehicle and determine, for example, the current traffic conditions based on the acquired environmental data. A top module equipped with multiple environmental sensors is also known as a Top Sensor Module (RSM). For this purpose, known environmental sensors send and / or receive appropriate electromagnetic signals, such as laser or radar beams, allowing for the generation of a data model of the vehicle's environment through signal evaluation, which is then used to control the vehicle.

[0005] Environmental sensors used to monitor and detect the vehicle's environment are typically mounted on the vehicle's roof, as this is usually the highest point and provides easy visibility of the surroundings. Environmental sensors are often placed as accessories on panel members that form the top skin of the roof module. When environmental sensors are in use, environmental conditions such as ice formation pose a risk of the translucent or transparent viewing area of ​​the sensor becoming covered in ice. This interferes with signal detection and, in the worst case, causes the viewing area to become completely opaque. For this reason, it is known to use cover elements, for example, with heating devices, to de-ice the transparent areas.

[0006] However, in the further development of such heating devices, particularly heating films, a problem has arisen regarding insufficient electrical contacts when connecting or integrating such heating devices in circuits. Specifically, in the injection molding process of this art, the heating device is covered and / or integrated with a plastic layer, such as a transparent polycarbonate (PC) layer, as a flat heating film. After the heating device is injection molded or as a cover element of the injection-molded part, the prior art requires the electrical contact areas of the heating device to be exposed again because they were covered by the plastic layer during the injection molding process. This requires high precision because the underlying conductor path used to establish electrical contacts is often a very thin layer, for example, no more than 0.1 mm. Alternatively, in the prior art, the electrical contacts can be covered by a suitable cover and / or cutout during the injection molding process, for example, they are not covered by the plastic layer during the injection molding process. In the case of the external heating film known in the prior art, the thickness of the cover element corresponds to no more than the thickness of the heating film and the coating of the heating film area. On the other hand, the remaining cover elements have a larger, more robust material thickness. This localized thinning can lead to optical marks, making the cover element susceptible to damage or puncture by external forces (flying stones, sharp objects, etc.), resulting in defects. The known internal heating film's heating conductor paths or heating layers form the inner surface of the cover element. These paths or layers are at most protected with a protective coating. However, the contact surfaces used for electrical connections are not coated; that is, they remain exposed. When using known two-component solutions, the heating film, except for the contact points, is coated with a second material component. In summary, known cover elements in sensor assemblies do not offer a satisfactory solution in terms of optics and / or manufacturing and / or robustness. Summary of the Invention

[0007] In view of the above-mentioned disadvantages and problems, the object of the present invention is to provide an enhanced sensor assembly and / or method that can at least alleviate the above-mentioned problems and disadvantages, and in particular improve the manner of electrical contact with the heating device.

[0008] This objective is achieved by a sensor assembly having the features of claim 1. Furthermore, this objective is achieved by a top module according to claim 14, which has at least one such sensor assembly, and by a motor vehicle according to claim 15, which has such a top module. Moreover, the object of the invention is achieved by a method having the features of claim 16.

[0009] Advantageous embodiments of the invention are the subject of the appended claims. Furthermore, any and all combinations of at least two features disclosed in the specification, claims, and / or drawings are within the scope of the invention. Of course, according to the invention, interpretations relating to the sensor assembly are equivalent to those relating to the top module and / or the vehicle, and do not need to be separately mentioned in their context. Similarly, disclosures of any and all features and embodiments related to the sensor assembly are equivalent to those relating to the method according to the invention, although not described verbatim. In particular, linguistically common paraphrasing and / or similar substitutions of corresponding terms within the scope of common linguistic practice, especially the use of synonyms supported by recognized linguistic literature, are of course included in the disclosure herein, without needing to explicitly mention every variation.

[0010] This invention proposes a sensor assembly for a motor vehicle, comprising: at least one sensor element that emits and / or detects electromagnetic radiation in at least one measurement direction to determine a measurement signal; a cover element disposed in front of the sensor element in at least one measurement direction, which is an injection-molded plastic part having at least one layer and being permeable to electromagnetic radiation; and a heating device including a plurality of conductor paths, which are applied to a backing film, particularly by screen printing or wire bonding, the backing film being molded to the cover element, the backing film including the conductor paths forming an insert of the injection-molded cover element, the conductor paths being at least partially located on the side of the backing film facing the sensor element. In other embodiments, the plurality of conductor paths may be deposited on the backing film as a plurality of conductor surfaces. The sensor assembly is characterized in that the conductor paths are preferably electrically interconnected by at least two busbars, and each of the at least two busbars at least partially forms an electrical connection element protruding and exposed from the cover element to allow for electrical contact. Particularly preferably, the sensor assembly includes at least a lidar sensor and a camera sensor.

[0011] The cover element preferably forms a viewing area through which at least one sensor element can transmit and / or receive electromagnetic radiation. The sensor element is preferably arranged relative to and / or on the cover element such that it can be observed through the cover element. Particularly preferably, the sensor element is configured to transmit and / or receive measurement signals in a measurement direction that specifically defines the primary measurement direction, preferably the optical axis for optical measuring elements. Preferably, the measurement direction defines a main conical axis around which a conical detection field opens within the sensor element. The conical opening angle is preferably sensor-specific and can be manipulated, particularly increased or decreased, as necessary by optical elements, such as lenses. At least two busbars preferably connect multiple conductor paths in series. If each busbar is connected to a voltage source, for example, via one or more cables, electrical energy can flow through multiple conductor paths. In this process, some electrical energy is converted into heat energy, which is how a heating effect can be provided. The heat is preferably emitted through the plastic layer to the outside of the cover element to melt ice formed on the cover element. In this way, a de-icing effect is achieved.

[0012] At least one sensor element is preferably at least a portion of an environmental sensor, particularly a lidar sensor and / or a radar sensor and / or a camera sensor and / or a multi-camera sensor and / or an ultrasonic sensor and / or a similar sensor. For example, the lidar sensor operates in the wavelength range of 905 nm or about 1550 nm. Preferably, the material of the cover element forming the viewing area of ​​the lidar sensor is permeable to the wavelength range used by the environmental sensor, and is therefore selected according to the wavelength used by the environmental sensor. The field of view of the environmental sensor preferably extends symmetrically in a cone shape around the optical axis of the environmental sensor, the cone shape having a sensor-specific cone opening angle.

[0013] According to the present invention, a method for producing a cover element of a sensor assembly includes the following steps: providing a backing film having a first side and a second side; coating a plurality of conductor paths and at least two busbars, particularly on the heating side or inner side of the film, by screen printing or wire bonding; introducing the backing film having the conductor paths, particularly in a generally U-shaped insertion, into a cavity of an injection mold, such that the two busbars protrude beyond the conductor paths; filling the cavity of the injection mold with a plastic material; hardening the plastic material in the cavity to form a cover element molded with the backing film; and demolding the cover element molded with the backing film. Particularly preferably, any type of heating structure including the two busbars is preferably screen-printed and / or wire bonded to the inner side of the backing film (e.g., where the + / - contacts are formed), and the backing film is made of, for example, PC material. The backing film is preferably made of the same material or plastic as the injection molding compound used to produce the cover element, so that the injection molding process preferably forms a stable and invisible connection. The backing film is preferably placed in a U-shape in the injection mold and covered at least once, but particularly preferably twice, by the injection-molded plastic. Preferably, lateral mold inserts that divert the film in a predetermined direction are used to place or fix the film in the U-shape within the injection mold. Preferably, the film is held in a central position between the two mold inserts by vacuum. For example, a first and / or second transparent plastic, at least transparent to the sensor element, is injection-molded onto the backing film. In other words, before the plastic is injected, a suitable support within the injection mold deflects the backing film, i.e., bends it into the U-shape of the present invention. The electrical connection elements and / or contacts formed on the busbars are preferably kept free during the injection molding process. For example, it is possible that the busbars cannot be covered by plastic if the contacts are close to the injection mold. Other coverings are also possible. In other aspects, the backing film is preferably covered and / or wetted and / or wrapped with at least one plastic layer around its perimeter. Particularly preferably, due to the geometry of the injection-molded part, an interface is formed, for example, configured to terminate a connection with the plug of at least one cable. This interface is preferably molded from injection-molded plastic.

[0014] Due to the configuration of the cover element according to the invention, its visual appearance can be significantly improved when the cover element is arranged on a vehicle and / or top module. In particular, the invention makes the heating device, especially the multiple conductor paths, appear more refined, for example, as if they are floating. On the other hand, the busbar is preferably larger than the multiple conductor paths and preferably protrudes from a specific planar portion of the cover element opposite to the measurement direction of the sensor element. This makes the busbar visually disappear, making no contact points visible from outside the vehicle. Similarly, the production of the cover element according to the invention is more cost-effective because it achieves a technically simple and cost-effective contact solution. In particular, according to the invention, the plug no longer needs to be integrated on the backing film or top. Therefore, manufacturers can at least save the originally complex contact process, such as welding electrical contacts. Thus, the reliability of the process and the robustness of the cover element are comprehensively improved.

[0015] In a preferred embodiment, after the injection molding process, the backing film is molded together with the conductor path to the cover element, such that connecting elements, at least partially formed by at least two busbars, are formed, particularly at the ends of the leg regions of the cover element, and each leg region preferably forms at least partially a mechanical contact. The cover element can have virtually any shape. Preferably, the cover element includes at least two legs that extend from the other planar cover element. The cover element can generally have a curved and / or arcuate, particularly convex, shape, with the two legs protruding from the bends. Particularly preferably, the cover element has a shape in which the two legs are substantially shorter than the leg connection. The planar portion of the cover element preferably defines the leg connection. Each of the two busbars is preferably contained in a corresponding leg, and each leg, except for its end, is preferably covered with injection-molded plastic. Particularly preferably, the leg regions are covered with a plastic that is opaque to the human eye, particularly appearing black, so that these regions are difficult to detect when the cover element is in the installed state. The end regions preferably describe the ends or head regions of the legs, each head region forming an electrical connection element. The head area is preferably not coated and / or covered with a plastic layer; instead, it is exposed for electrical contact.

[0016] Particularly preferably, the plastic injection-molded in the two leg regions forms part of the insert connection. For this purpose, for example, negative plates for inserting and / or clamping and / or fixing connections can be injection-molded in the leg regions of the injection mold, such that corresponding inserting and / or clamping and / or fixing connections are generated during plastic injection.

[0017] Particularly preferably, the cover element, as an injection-molded part, comprises at least two plastic layers, which are preferably made of different plastics with good bonding properties with each other. The first plastic layer is preferably transparent in the wavelength range visible to the human eye, and may be made of polycarbonate, for example. The first plastic layer may be injection-molded onto the backing film in areas of the planar portion of the cover element, particularly in the area of ​​the leg joint. The second plastic layer is preferably opaque, i.e., impermeable, in the wavelength range visible to the human eye, for example, black. Particularly preferably, the backing film is covered with the second plastic layer at least in the leg area. The first and second plastic layers are preferably permeable to the wavelength range used by the sensor element. If the first plastic layer is transparent, it is preferably an opaque, particularly black, second plastic layer laminated throughout the cover element within the mold. If the first plastic layer is opaque, particularly black, it is preferably laminated in the area between the two legs, particularly in a partial mold. The second layer is particularly preferably formed at least in the leg area. When viewed from outside the vehicle, the heating conductor channel appears to float, preferably in the area of ​​the transparent plastic. These floating conductor paths disappear at both ends of the cover element, especially where the cover element meets the leg area, because they are deflected into the opaque, particularly black, plastic. Therefore, the busbar path is preferably located behind the opaque plastic, without occupying any space in the visible area of ​​the cover element. This avoids the need for additional black printing to cover the busbar. Furthermore, the area occupied in the externally visible region is also smaller. This improves the optical quality of the cover element.

[0018] In a preferred embodiment, two leg regions of the cover element protrude from the cover element in the opposite direction to the measurement direction. Preferably, the leg regions of the cover element protrude from the cover element in the opposite direction to the direction observed by the sensor element. Preferably, when the cover element is mounted on a motor vehicle, the leg regions protrude towards the interior of the motor vehicle.

[0019] In a preferred embodiment, the busbar is arranged at least partially in the corresponding leg area of ​​the cover element and is preferably covered with injection-molded plastic, particularly preferably with a plastic layer that is opaque to the human eye, especially black plastic. Particularly preferably, the connecting element formed at the end is thus exposed and, more preferably, can be electrically contacted therewith. For this purpose, it is preferable to form a mechanical connection in the leg area by at least one layer of injection-molded plastic with a suitable geometry.

[0020] Particularly preferably, the cover element comprises an outer side facing the vehicle environment and an inner side facing the sensor element, with a backing film disposed on the outer side of the cover element. Of course, in other embodiments, the backing film may also be disposed on the inner side. Particularly preferably, disregarding other coatings after the injection molding process, the backing film is the outermost layer of the cover element. Preferably, the backing film including conductor paths applied thereon, such as those printed thereon, forms the outermost layer of the cover element, particularly the outermost layer in certain areas. In this case, the backing film is the outermost layer. The conductor paths are arranged on the side of the backing film facing the sensor element to protect the pathway. Alternatively, the backing film may also be internally integrated into the first injection-molded component. This can be advantageous because it eliminates the need for U-shaped deflection of the backing film, in particular, during the production of the cover element.

[0021] The cover plate of the sensor assembly according to the invention can be made of at least one polycarbonate material or other materials suitable for the application. Additionally, it is preferable that some and / or parts of the cover element are made of different plastics to provide different optical properties, for example, in different areas of the cover element.

[0022] Accordingly, in a preferred embodiment, the backing film of the sensor assembly according to the invention comprises or is made of at least one polycarbonate material. The backing film is preferably made of the same plastic as the cover element or the body of the cover element. The plastic of the cover element preferably comprises a plastic substrate, preferably mixed with at least one additive to adjust optical and / or mechanical properties. For example, the additive may make the substrate material opaque, preventing light transmission to wavelengths within the visible range.

[0023] In an advantageous embodiment of the sensor assembly according to the invention, the cover element has a protective coating on its outer side facing the vehicle environment to protect it from damage and abrasion. Particularly preferably, the protective coating is provided on the outward-facing side of the outer backing film. This protective coating may comprise a coating system applied in one or two layers, providing scratch, weather, and / or chemical protection. The coating system used may be a thermosetting system or a coating system that cures under ultraviolet radiation. The coating system may be applied by spraying or flow spraying.

[0024] Advantageously, the refractive index of the protective coating is lower than that of the injection-molded plastic material of the cover element. This can improve the propagation behavior of the cover element.

[0025] In a preferred embodiment, the cover element at least partially comprises a first plastic member that is opaque to the human eye but transparent to at least one sensor element, particularly a lidar sensor. Alternatively or additionally (i.e., and / or), the cover element at least partially comprises a second plastic member that is transparent to the human eye and to at least one sensor element, particularly a camera or camera sensor. Therefore, the cover element preferably comprises two plastic members that differ at least in their transparency (particularly for visible light wavelengths). Both the first and / or second plastic members may have one or two layers, or be made of a single plastic material or a multi-component plastic material. Preferably, the cover element has an area made of the first plastic member and at least one other area made of the second plastic member. By providing the first plastic member, the cover element is preferably black, so that it preferably blends visually with the rest of the vehicle body. By providing the second plastic member, an additional area can be formed through which a sensor element operating in the visible light band can transmit and / or receive electromagnetic signals.

[0026] In a preferred embodiment, the backing film is at least partially in-mold laminated and / or covers a first plastic member that is opaque to the human eye but transparent to at least one sensor element, particularly a lidar sensor. Alternatively or additionally (i.e., and / or), the backing film is at least partially in-mold laminated and / or covers a second plastic member that is transparent to the human eye and at least one sensor element, particularly a camera or camera sensor. Therefore, the backing film is preferably formed on the outer side of the cover element (relative to the measurement direction).

[0027] The sensor assembly according to the invention can be arranged virtually anywhere in the vehicle and / or roof module and can be configured for different purposes. For example, the sensor assembly is integrated into the vehicle roof, particularly the roof module, which at least partially forms the vehicle roof and is therefore preferably formed as part of an automated or semi-automatic driving system for the vehicle. In this case, the cover element preferably forms the outer skin element of the vehicle roof, i.e., particularly a fixed top portion that is not movable relative to the vehicle structure. The sensor assembly can also potentially be placed on the vehicle roof and / or roof module, which is a dome. In this case, the cover element at least forms part of the housing of the sensor assembly, which houses the sensor assembly. Particularly preferably, the vehicle and / or roof module may include multiple sensor assemblies and / or multiple cover elements.

[0028] In another alternative embodiment, the cover element forms an outer skin element at the front or rear of the vehicle. In this case, the sensor assembly can also be part of adaptive cruise control, parking assistance, and / or any other safety features related to the vehicle.

[0029] In a preferred embodiment, a top module for forming the roof of a motor vehicle is provided, the top module comprising: a panel member that at least partially forms a top skin of the vehicle roof, the top skin serving as an outer sealing surface of the top module; and at least one sensor assembly according to any embodiment of the invention.

[0030] Additionally, the invention preferably relates to a motor vehicle comprising a body and at least one such roof module, which is arranged as a structural unit on the body, particularly by adhesive and / or screw fixing and / or welding and / or soldering to the body.

[0031] Conductor paths can be applied to the backing film by any method. Screen printing, hot stamping, and transfer printing are all possible methods. Screen printing, dispensing, hot stamping, and transfer printing will be mentioned as specific examples. Furthermore, suitable curing methods, such as laser curing, can be used to harden the conductor paths.

[0032] In addition, conductor paths can be applied to a wide membrane web or preform, the size of which is consistent with the size of the backing membrane, or consistent with the backing membrane placed in the cavity.

[0033] When injection molding cap components, a backing film or preform is wrapped so that it is covered with plastic material on the side where the conductor path is arranged.

[0034] The method according to the invention is specifically configured in such a manner that the backing film, already having conductor paths and busbars, is unwound from the first roll. The backing film can then be die-cut to produce a film cross-section with conductor paths, which is placed, particularly by a robot, into an injection mold and overmolded together with plastic material within the cavity of the injection mold. After the cover element is demolded from the cavity of the injection mold, the cover element is preferably coated with a protective coating, particularly on the outer backing film, to protect it from scratches, weather, and / or chemicals.

[0035] Of course, the embodiments and illustrative examples mentioned above and discussed below can be implemented individually and in any combination without departing from the scope of the invention. Furthermore, the embodiments and illustrative examples mentioned above and discussed below are also equivalent to or at least similar to the top module according to the invention, without needing to be mentioned separately in its context. Attached Figure Description

[0036] Embodiments of the present invention are illustrated in the accompanying drawings and will be discussed below by way of example.

[0037] Figure 1 This is a schematic diagram of a motor vehicle including a top module and a sensor assembly according to an exemplary embodiment of the invention;

[0038] Figure 2 This is a first schematic diagram of a top module including an exemplary embodiment of a sensor assembly according to the present invention;

[0039] Figure 3 This is a second schematic diagram of a top module including an exemplary embodiment of a sensor assembly according to the present invention;

[0040] Figure 4 This is a third schematic diagram of a top module including an exemplary embodiment of a sensor assembly according to the present invention;

[0041] Figure 5 This is a fourth schematic diagram of a top module including an exemplary embodiment of a sensor assembly according to the present invention;

[0042] Figure 6 This is a fifth schematic diagram of a top module including an exemplary embodiment of a sensor assembly according to the present invention;

[0043] Figure 7 This is a first detailed view of an exemplary embodiment of a sensor assembly according to the present invention;

[0044] Figure 8 This is a second detailed view of an exemplary embodiment of the sensor assembly according to the present invention;

[0045] Figure 9 This is a third detailed view of an exemplary embodiment of a sensor assembly according to the present invention;

[0046] Figure 10 This is a fourth detailed view of an exemplary embodiment of the sensor assembly according to the present invention;

[0047] Figure 11 This is a fifth detailed view of an exemplary embodiment of a sensor assembly according to the present invention;

[0048] Figure 12 This is a sixth detailed view of an exemplary embodiment of the sensor assembly according to the present invention;

[0049] Figure 13 This is a seventh detailed view of an exemplary embodiment of the sensor assembly according to the present invention;

[0050] Figure 14 This is an eighth detailed view of an exemplary embodiment of a sensor assembly according to the present invention; and

[0051] Figure 15 This is a ninth detailed view of an exemplary embodiment of a sensor assembly according to the present invention. Detailed Implementation

[0052] Figure 1 A motor vehicle is shown. A top module 10 is formed on a body 102, particularly on a top frame 104 of the body 102. The top module 10 includes a panel member 11, which at least partially forms the top skin of the vehicle top 12, the top skin serving as the outer sealing surface of the top module 10. For example, the panel member 11 is an injection-molded part made of plastic or glass; in this case, it is made of polycarbonate.

[0053] The top module 10 also includes at least one sensor assembly 16 according to the invention. The sensor assembly 16 includes a cover element 18, which preferably forms part of a sensor housing, in which at least one sensor element 20 is disposed. In this embodiment, the cover element 18 covers the camera opening 19 of the panel member 11 and preferably seals the camera opening 19 in a moisture-proof manner relative to the vehicle environment (see [link to documentation]). Figure 7 At least one sensor element 20, such as a camera 23, observes through a camera opening 19. In this case, the cover and 18 form a transparent area, specifically a window, through which at least one sensor element 20 observes. In this embodiment, at least one sensor element 20 also includes a lidar sensor 21 that emits a laser in the measurement direction x, the laser passing through the cover and 18 as an electromagnetic signal. The lidar sensor 21 is configured to transmit and / or receive electromagnetic signals and evaluate them using an evaluation device, for example, on which the vehicle environment can be reconstructed (see...). Figure 3 and 6 The lidar sensor 21 is preferably positioned behind the cover element 18 so that it can be observed through the black in-mold laminated area of ​​the cover element 18, which is preferably opaque to the human eye.

[0054] The cover element 18 includes an injection-molded body 22 made of polycarbonate material, on which a backing film assembly is disposed. The body 22 includes an inner side 24 facing at least one sensor element 20 and an outer side 28 facing the vehicle environment. The backing film assembly is preferably positioned on the outer side 28. The backing film assembly preferably has a protective coating 30 that is scratch-resistant, weatherproof, and chemically resistant, and is made by a coating system (see, for example, [link to coating system]). Figures 13 to 15 ).

[0055] The backing film assembly includes a backing film 32 made of polycarbonate material and provided with a plurality of conductor paths 34, which are heating devices for the cover element 18. The backing film 32 is arranged on the outer side 28 of the body 22. The conductor paths 34 are arranged on the side of the backing film 32 facing the sensor element 20.

[0056] In addition, the backing membrane assembly includes two busbars 38 that are conductively connected to the conductor path 34. The busbars 38 are significantly larger than the conductor path 34. The cover element 18 can have any geometry, for example, it can be... Figures 7 to 15 The geometry seen in different views. The busbar 38 is contained within two leg regions 40 of the cover element 18, which protrude beyond the planar leg connection 42 and are covered by a plastic layer or a second plastic member 37 made of a first plastic. This is preferably different from the plastic of the body 22, at least in terms of material thickness, which is disposed in the region of the leg connection 42. Particularly preferably, the plastic of the leg regions 40 is opaque to the human eye and appears black (not visualized in the figures). Particularly preferably, the cover element 18 comprises two distinct plastic members. The first plastic member 36 is preferably opaque to the human eye (particularly for wavelengths in the visible light range) and appears, for example, black. Preferably, the first plastic member 36 is permeable to the wavelengths used by the lidar sensor 21. Preferably, the cover element 18 includes a second plastic member 37, which is transparent to the human eye (particularly for wavelengths in the visible light range). The cover element 18 is preferably partially made of the first plastic member 36 and / or the second plastic member 37. For example, the cover element 18 may be made of a second plastic component 37 in the area of ​​the camera 23 (in the see-through area of ​​the camera 23), through which the camera 23 is able to perform optical detection of the vehicle environment (see...). Figure 8 The transparent area of ​​the lidar sensor 21 is preferably at least in-mold laminated with the first plastic component 36, and therefore preferably appears black, and in particular opaque, to the human eye. Preferably, the cover element 18 is also made of or includes the first plastic component 36 in the leg area. Figure 14 and 15 Additionally, a cover element 18 is shown that does not have a transparent area or an area made of a second plastic component 37.

[0057] Both busbars 38 at least partially form electrical connection elements that protrude from the cover element 18, particularly from the planar leg connection portion 42, and are exposed to allow for electrical contact. Particularly preferably, each leg region 40 forms a mechanical contact portion 44, where the cover element 18 can be connected to the circuit via a cable (see...). Figure 7 , 9 11 and 12).

[0058] List of reference numerals

[0059] 10 Top Modules

[0060] 11 Panel Components

[0061] 12 vehicle roofs

[0062] 16 sensor assembly

[0063] 18 cover components

[0064] 19 camera openings

[0065] 20 sensor elements

[0066] 21 LiDAR Sensors

[0067] 22Ontology

[0068] 23 cameras

[0069] 24 inner side

[0070] 28 outer side

[0071] 30 protective coating

[0072] 32 backing film

[0073] 34 Conductor Path

[0074] 36 First Plastic Component

[0075] 37 Second Plastic Component

[0076] 38 busbars

[0077] 40 Leg Area

[0078] 42 Leg connection section

[0079] 44 Mechanical Contact Part

[0080] 102 body

[0081] 104 Body Roof Frame

Claims

1. A sensor assembly for a motor vehicle, the sensor assembly comprising: At least one sensor element (20) emits and / or detects electromagnetic radiation in at least one measurement direction to determine a measurement signal; A cover element (18) is arranged in front of the sensor element (20) in the at least one measuring direction, the cover element being an injection-molded plastic part having at least one layer and being permeable by the electromagnetic radiation; The heating device includes a plurality of conductor paths (34) applied to a backing film (32) molded to the cover element (18), the backing film (32) including the conductor paths (34) forming an insert of the injection-molded cover element (18), the conductor paths (34) being at least partially located on the side of the backing film (32) facing the sensor element (20), characterized in that the conductor paths (34) are electrically interconnected by at least two busbars (38), each of the at least two busbars (38) forming at least partially an electrical connection element protruding and exposed from the cover element (18) to enable electrical contact.

2. The sensor assembly according to claim 1, characterized in that, After the injection molding process, the backing film (32) and the conductor path (34) have been molded together onto the cover element (18) such that an electrical connection element formed at least partially by the at least two busbars (38) is formed at the end of the corresponding leg region (40) of the cover element (18), at least a portion of the leg region forming a mechanical contact (44).

3. The sensor assembly according to claim 2, characterized in that, The two leg regions of the cover element (18) protrude from the cover element opposite to the measuring direction.

4. The sensor assembly according to claim 2 or 3, characterized in that, The busbar (38) is at least partially disposed in the corresponding leg region of the cover element (18) and is covered by injection-molded plastic, with exposed electrical connection elements formed at the ends.

5. The sensor assembly according to any one of the preceding claims, characterized in that, The cover element (18) includes an outer side (28) facing the vehicle environment and an inner side (24) facing the sensor element (20), with the backing film (32) disposed on the outer side (28).

6. The sensor assembly according to any one of the preceding claims, characterized in that, The plastic of the cover element (18) is made of at least one polycarbonate material.

7. The sensor assembly according to any one of the preceding claims, characterized in that, The backing film (32) comprises at least one polycarbonate material.

8. The sensor assembly according to any one of the preceding claims, characterized in that, The cover element (18) has a protective coating (30) on its outer side.

9. The sensor assembly according to claim 8, characterized in that, The refractive index of the protective coating (30) is lower than that of the plastic material of the cover element (18).

10. The sensor assembly according to any one of the preceding claims, characterized in that, The cover element (18) includes at least partially a first plastic component (36) that is opaque to the human eye but transparent to the at least one sensor element (20), and / or the cover element (18) includes at least partially a second plastic component (37) that is transparent to both the human eye and the at least one sensor element (20).

11. The sensor assembly according to claim 10, characterized in that, The first plastic component is transparent to the lidar sensor (21), and / or the second plastic component is transparent to the camera (23).

12. The sensor assembly according to any one of claims 1 to 9, characterized in that, The backing film (32) is at least partially in-mold laminated and / or covered with a first plastic component (36), which is opaque to the human eye but transparent to the at least one sensor element (20), and / or the backing film (32) is at least partially in-mold laminated and / or covered with a second plastic component (37), which is transparent to both the human eye and the at least one sensor element (20).

13. The sensor assembly according to claim 10, characterized in that, The first plastic component is transparent to the lidar sensor (21), and / or the second plastic component is transparent to the camera (23).

14. The sensor assembly according to any one of claims 1 to 13, characterized in that, The cover element (18) is the outer skin element of the vehicle roof (12).

15. The sensor assembly according to any one of claims 1 to 13, characterized in that, The cover element (18) is an outer skin element at the front or rear of the vehicle.

16. A top module for forming a vehicle roof (12) of a motor vehicle, comprising: A panel member (11) that at least partially forms the top skin of the vehicle roof (12), the top skin serving as the outer sealing surface of the top module (10); And at least one sensor component (16) according to any one of claims 1 to 14.

17. A motor vehicle, comprising a body (102) and a top module (10) according to claim 16, the top module (10) being placed on the body (102) as a structural unit.

18. A method for producing a cover element for a sensor assembly in a motor vehicle, the method comprising the steps of: Provide a backing film having a first side and a second side; Multiple conductor paths and at least two busbars are applied to the first side of the backing membrane; A backing film having the conductor path is introduced into the cavity of the injection mold such that the two busbars protrude beyond the conductor path; The cavity of an injection mold is filled with at least one plastic material, such that both busbars form electrical connection elements that remain separate from the plastic material; the plastic material in the cavity is hardened to form a cover element molded with the backing film; and the cover element molded with the backing film is demolded.

19. The method according to claim 18, characterized in that, Multiple conductor paths and at least two busbars are applied to the first side of the backing film by screen printing or wire laying; the backing film having the conductor paths is inserted into the cavity of the injection mold; The at least one plastic material includes a first plastic component and / or a second plastic component.

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