Vehicle body panel assembly with integrated functional component, vehicle and manufacturing method thereof

Abstract

The present disclosure relates to a vehicle body panel assembly comprising: a structural element; a connection interface for connecting the structural element to the vehicle body; a sound module including an exciter coupled to the structural element; a light source coupled to the structural element; and components coupled to the structural element from a list of the following components: a navigation unit, a communication unit, an antenna unit, a lighting unit, a signal lamp unit, a light-emitting unit, a heating unit, a cleaning unit, a design element, a lighting cover plate lens, a sensor cover plate lens, a sensor housing, a radar radome, a laser radar radome, a safety unit and a camera unit. A parking system unit, a symbol unit and a sensor unit. The exciter is configured to cause the structural element to oscillate within a given frequency band. The invention also relates to a vehicle comprising the vehicle body panel assembly, a method for manufacturing the vehicle body panel assembly and a method for manufacturing the vehicle.

Description

Technical Field

[0001] The present disclosure generally relates to vehicle exterior body panel assemblies. Such panel assemblies may be uniquely shaped panels that provide coverage for vehicle systems and are capable of protecting occupants from the elements and during a collision.

[0002] The present disclosure more particularly relates to a vehicle body panel assembly having an integrated component and a vehicle body panel portion, such as a mask. In addition, the present disclosure relates to a vehicle including the vehicle body panel assembly, a method for manufacturing a vehicle body panel assembly, and a method for manufacturing a vehicle. Background Art

[0003] Vehicles are equipped with more and more electronic components, especially sensors for sensing the environment. These components need to be placed in a given structure of the vehicle.

[0004] This increases the number of components, the complexity of the final product (e.g., the front of a car panel), and the complexity of assembly, all of which also directly increase costs.

[0005] Document DE 10 2014 104 944 A1 discloses a radar sensor design in which, instead of providing the radar sensor with a conventional housing, the antenna is directly covered with another material, such as a polymer or a coating, eliminating the gap between the antenna and the housing.

[0006] The paper "Conformal Superstrate Loaded Automotive Radar Antennas for Integration in Polymer Body Panels, Proceedings of the 4th European Antennas and Propagation Conference, 2010" by Andreas Kilian and Lorenz-Peter Schmidt describes a design and method for post-molding a radar antenna into a plastic part of a body panel, where a 24 GHz antenna is fabricated and copper is hot-stamped onto a polymer foil. The final structure from front to back includes the lacquer foil, antenna foil (with antenna and ground plane), and post-molding material.

[0007] Document EP3336575A1 describes an antenna as part of a radome. The radome forms a dielectric resonator which, in combination with an antenna element, forms a radar sensor. This document relates to slot antennas rather than patch antennas, which are now mainly used in radar sensors and use a different technology.

[0008] Document DE102016210769A1 describes a plurality of thin film antennas for 360° field of view coverage. The document involves the use of a plurality of thin film antennas that are manufactured on a flat foil and attached (e.g. glued to) different parts of a vehicle by means of an adhesive layer to ensure complete coverage of the surroundings. This helps to reduce the number of complete radar sensor units by placing the antennas in different locations on the vehicle.

[0009] Document DE102014214329A1 proposes using a decorated and heated radar cover as a radome. A foil formed from the back is used to achieve decoration, heating, isolation and filtering of radar signals. Thus, the housing of the radar sensor itself serves as an external radome, which can be used as a radar unit cover or as a component integrated into a vehicle bumper.

[0010] While the documents cited above outline the possibility of simplifying the assembly of radar sensors and radomes or integrating radar antennas into plastic materials, the final products are either simple components that still need to be assembled into the vehicle body, such as a mask, or do not incorporate all the functions required by the manufacturer and may even directly affect and improve the functioning of the radar system itself, such as the heating system. Summary of the invention

[0011] In view of the foregoing, one object of the present disclosure is to provide a vehicle body panel assembly that enables vehicle manufacturers to reduce the number of components and / or the complexity of assembly.

[0012] Another object of the present disclosure is to provide a vehicle including a vehicle body panel assembly, a method for manufacturing a vehicle body panel assembly, and a method for manufacturing a vehicle including a vehicle body panel assembly.

[0013] According to one aspect of the present disclosure, a vehicle body panel assembly is provided.

[0014] The vehicle body panel assembly disclosed herein includes: at least one structural element; a connection interface for connecting the at least one structural element to the vehicle body; at least one sound module including at least one exciter, the at least one exciter coupled to the at least one structural element; at least one light source coupled to the at least one structural element; and at least one component from the following list of components coupled to the at least one structural element: at least one navigation unit, at least one communication unit, at least one antenna unit, at least one lighting unit, at least one signal light unit, at least one light emitting unit, at least one heating unit, at least one cleaning unit, at least one design element, at least one lighting cover lens, at least one sensor cover lens, At least one sensor housing, at least one radome, at least one lidar radome, at least one security unit, at least one camera unit, at least one parking system unit, at least one symbol unit and at least one sensor unit, in particular at least one radar sensor unit, at least one ultrasonic sensor unit or at least one parking sensor unit (e.g. for 24 GHz, 77 GHz or 79 GHz technology or any other frequency range), at least one lidar (light detection and ranging) unit, at least one ultrasonic sensor unit and / or at least one parking sensor unit (e.g. for a parking distance control system), wherein the at least one actuator is configured to cause the at least one structural element to oscillate within a given frequency band.

[0015] It should be noted that other components not mentioned in the above list may also be fixedly attached to the structural element. Furthermore, the list of components that may be included in the vehicle body panel may be varied, in particular by deleting one or more of the components mentioned in the list.

[0016] In the context of the present invention, vehicle body panels are to be understood as also including openings on the outside of the vehicle body, such as windows and glass panels of the roof.

[0017] In the context of the present invention, a structural element is understood to be an element suitable for carrying an actuator, preferably a vehicle body panel in the form of a transparent / translucent polycarbonate lens, which may optionally have the function of an optical lens. Alternatively, the structural element may be an additional internal component, such as a bezel or a housing of a vehicle body panel assembly.

[0018] In the context of the present invention, a frequency band may include a single frequency or a plurality of frequencies.

[0019] Due to the integration of at least two components into a structural element, the vehicle body panel assembly provides a complex combination of multiple functions that have hitherto been considered as separate components. Thus, the vehicle body panel assembly according to the present disclosure forms a "multifunctional" vehicle body panel assembly, which reduces the number of components, weight, packaging space, cost and complexity of assembly, and improves the tolerance chain. Thus, the vehicle body panel assembly can form a so-called phygital shield for a vehicle.

[0020] The vehicle may be a motor vehicle or an electric vehicle (such as a car, truck, bus, scooter or motorcycle) or a van or a bicycle or a rail vehicle (such as a train or tram) or a water vehicle (such as a ship, boat) or an air vehicle (such as an airplane, helicopter or aircraft) or any other vehicle.

[0021] The invention disclosed herein is based on integrating multiple components into a vehicle body panel assembly. In particular, at least one sound module including an exciter (e.g., a piezoelectric element, a linear resonant actuator, a solenoid, or any other similar device) coupled to the at least one structural element is integrated into the vehicle body panel assembly. The at least one exciter is configured to cause the at least one structural element to oscillate within a given frequency band. Thus, the structural element is used to transmit waves oscillating within the given frequency band to the environment.

[0022] By using at least one exciter of the vehicle body panel assembly disclosed herein, waves oscillating within a given frequency band are directed into the structural element and into the environment without the use of membranes or loudspeakers. Thus, the vehicle body panel assembly can be installed in a vehicle shell in direct contact with water without the risk of damaging the sound module.

[0023] Thus, by using structural elements of the vehicle body panel assembly as oscillators stimulated by at least one exciter of at least one sound module, cost and weight intensive structures for shielding the sound module from environmental influences can be avoided. Thus, the vehicle body panel assembly disclosed herein is very light and strong.

[0024] Furthermore, the waves generated by oscillating the structural elements of the vehicle body panel assembly disclosed herein are directly transmitted to the environment, thus being very energy efficient. For example, a warning sound to warn pedestrians can be directly transmitted to the pedestrians, thus eliminating the need for a loud source such as a speaker covered by the vehicle body structure.

[0025] The vehicle body panel assemblies disclosed herein include connection interfaces, such as a plurality of clips and / or screws, and / or geometric configurations that facilitate the vehicle body panel assembly into a predetermined position relative to a vehicle frame or subframe.

[0026] The at least one light source of the vehicle body panel assembly may be an LED, a laser, a display, or any other type of light source.

[0027] In some embodiments, the plurality of components fixedly attached to the structural element may include at least three, four, or five components from the list of components disclosed above.

[0028] In some embodiments, the at least one actuator is fixedly attached to the structural element.

[0029] In order to fixedly attach the at least one actuator to the structural element, the at least one actuator can be covered by the structural element itself, for example by profiled structural element.

[0030] The at least one exciter may be attached to the structural element directly or indirectly (eg via an additional component). However, the at least one exciter is mechanically coupled to the structural element such that oscillations of the at least one exciter are introduced into the structural element.

[0031] In some embodiments, the structural element comprises a lens, in particular a front physical digital guard.

[0032] A lens, for example a part of the front end of a vehicle carried by the subframe, in particular a part that directs the airflow into the interior of the vehicle, can be used as a structural element because it provides a large surface for generating waves within a given frequency band. In particular, the lens can be used to generate sounds that can be heard by humans.

[0033] In some embodiments, the at least one sound module comprises at least one sound source configured to generate and / or amplify a sound signal to the at least one actuator so that the sound signal is converted into sound waves by the at least one structural element.

[0034] The sound source may include a sound processor and / or an amplifier.The sound source may be attached to the structural element or at a distance from the structural element and connected to the at least one exciter via an interface, such as a wired or wireless connection.

[0035] In some embodiments, the vehicle body panel assembly comprises as the at least one component at least one sensor unit, which is fixedly attached to the structural element and at least partially integrated in the structural element.

[0036] By fixedly attaching at least one sensor unit to the structural element, the vehicle body panel assembly serves as a carrier for providing a variety of technologies for interacting with the environment. Thus, by installing the vehicle body panel assembly to a vehicle, the vehicle can be equipped with a variety of technologies for interacting with the environment.

[0037] In some embodiments, the structural element is a shaped structure.

[0038] By forming the structural element from a mold, components attached to the structural element may be covered by the mold such that the components form an integral part of the vehicle body panel assembly.

[0039] Thus, in some embodiments, the connection interface, the at least one sound module, the at least one light source and the at least one component are at least partially integrated into a structural element.

[0040] In some embodiments, the connection interface is configured to mechanically connect the vehicle body panel assembly to the front, rear, side, or top of the vehicle.

[0041] The connection interface may accordingly form a corresponding structure of a vehicle to which the vehicle body panel assembly is to be attached.

[0042] In some embodiments, the vehicle body panel assembly further comprises a socket and / or a cable, in particular exactly one socket and / or exactly one cable, for electrically connecting the vehicle body panel assembly to an external electrical component.

[0043] By using the socket and / or the cable, electrical signals for charging and / or communicating with components of the vehicle body panel assembly can be exchanged with external electrical components (eg, a sound processor or a voltage source).

[0044] According to another aspect of the present invention, a vehicle is disclosed, which includes at least one embodiment of the vehicle body panel assembly disclosed herein.

[0045] According to another aspect of the present invention, a method for manufacturing one embodiment of the vehicle body panel assembly disclosed herein is disclosed.

[0046] The method comprises: a molding process for producing a structural element, in particular an inmolding and / or overmolding and / or 2K molding and / or a more than 2K molding process; and an attaching process for fixedly attaching at least one sound module, at least one light source and at least one component to the structural element.

[0047] In some embodiments, during the molding process, the at least one sound module, the at least one light source and the at least one component are attached to the structural element by at least partially covering them with molding material.

[0048] According to another aspect of the present invention, a method for manufacturing a vehicle is disclosed. The method includes installing an embodiment of the vehicle body panel assembly disclosed herein on the vehicle.

[0049] In some embodiments, the vehicle body panel assembly is installed on the vehicle as a separate part. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The present disclosure will now be described by way of non-limiting examples only and with reference to the accompanying drawings, in which:

[0051] Figure 1 A schematic diagram showing an exemplary vehicle body panel assembly according to the present invention;

[0052] Figure 2 Another example of a vehicle body panel assembly according to the present invention is shown;

[0053] Figures 3 to 9 shows illustrative examples of portions of a vehicle body panel assembly according to the present invention;

[0054] Fig.10 An example of a vehicle according to the present invention is shown;

[0055] Fig.11 One example of a method for manufacturing a vehicle body panel assembly according to the present invention is shown. DETAILED DESCRIPTION

[0056] exist Figure 1 1 shows a vehicle body panel assembly 100. The vehicle body panel assembly 100 comprises a first structural element 101, a second structural element 102 and a third structural element 103, a connection interface 104 for connecting at least one structural element to a vehicle body, a sound module 105 comprising an actuator 106, a light source 107 and another component 110 such as a design element or a sensor.

[0057] The first structural element 101 forms a lens covering the panel, the second structural element 102 forms a support structure for mechanically reinforcing the vehicle body panel assembly 100 , and the third structural element 103 forms an outer shell of the vehicle body panel assembly 100 , ensuring the water tightness of the vehicle body panel assembly 100 .

[0058] exist Figure 1, for illustrative purposes, the exciter 106 is attached to the first structural element 101 and the light source 108 is attached to the second structural element 102. However, the sound module 105, in particular the exciter 106 and the light source 108, may be attached to the first structural element 101, the second structural element 102 and / or the third structural element 103 in any combination.

[0059] The light source 108 may be an LED, a laser, a light guide, a display, or any other type of light source.

[0060] In particular, at least one actuator 106 may be attached to the first structural element 101 , the second structural element 102 and / or the third structural element 103 .

[0061] In particular, at least one light source 108 may be attached to the first structural element 101, the second structural element 102 and / or the third structural element 103, such as Figures 3 to 9 shown.

[0062] When activated, the actuator 106 induces a movement at a given frequency in the first structural element 101 , so that the first structural element 101 oscillates at the given frequency and transmits waves, in particular sound waves, at the given frequency in the surroundings as indicated by line 107 .

[0063] When activated, the light source 108 transmits light in the environment, as indicated by arrows 109. Thus, the first structural element 101 is at least partially transparent.

[0064] By using the connection interface 104, the vehicle body panel assembly 100 can be installed as a whole to a vehicle, such as a Figure 3 The vehicle 200 is shown. Thus, installation of the vehicle body panel assembly 100 with all its components is time and space efficient.

[0065] exist Figure 2 Another embodiment of a vehicle body panel assembly 100 is shown in . Here, only the first structural element 101 is used to accommodate both the sound module 105 including the exciter 106 and the light source 108 .

[0066] Figure 2 The vehicle body panel assembly 100 shown in FIG. 1 may be, for example, a grille of a vehicle.

[0067] exist Figure 3 In FIG. 1 , the light source 108 is attached to the third structural element 103 .

[0068] exist Figure 4 In FIG. 1 , the light source 108 is attached to the first structural element 101 .

[0069] exist Figure 5In the embodiment shown in FIG. 1 , the light source 108 is integrated in a hole in the third structural element 103 , which results in good cooling and replaceability of the light source 108 .

[0070] exist Figure 6 In the embodiment, the light source 108 is attached to the second structural element 102, which may be a carrier for carrying the light source 108 or may be a frame. Therefore, the light source 108 may be a display for displaying graphics on the second structural element 102, which can be seen when the first structural element 101 is viewed from the environment.

[0071] exist Figure 7 In FIG. 1 , an exciter 106 is attached to the third structural element 103 , which causes the outer shell of the vehicle body panel assembly 100 to oscillate.

[0072] exist Figure 8 In FIG. 1 , an actuator 106 is attached to the first structural element 101 , which causes the lens of the vehicle body panel assembly 100 to oscillate.

[0073] exist Fig. 9 In the embodiment of the present invention, the exciter 106 is attached to the second structural element 102 , which causes the interior components of the vehicle body panel assembly 100 , particularly the bezel, to oscillate.

[0074] exist Fig.10 A vehicle 200 is shown in FIG. The vehicle 200 includes a multifunctional vehicle body panel assembly 201 mounted at the front of the vehicle 200 .

[0075] The vehicle body panel assembly 201 includes a structural element 203 made of a molded material and the following functional components: a radar antenna cover 205, a radar antenna 207, a cover 209, a graphic design (e.g. a painted part, a metallized part 211), a graphic design (e.g. a body color 213), a cover lens 215 for a lidar, a (luminous) symbol or a radar antenna cover 217, a surface luminous part 219, a heating unit 221, a cover lens 223 for lighting, a light source 225, a cover lens 227 for lighting, a vehicle-to-vehicle communication module 229 and a sound module 231.

[0076] exist Fig.11 The method for manufacturing the Figure 1 A method 300 of a vehicle body panel assembly 100 is provided.

[0077] The method 300 comprises: a molding step 301 of producing the structural elements 101, 102, 103, in particular an inner molding and / or over molding and / or 2K molding and / or more than 2K molding process; and an attachment step 303 of fixedly attaching at least one sound module 105, at least one light source 108 and at least one component to the structural elements 101, 102 and / or 103.

[0078] Although the present disclosure provides multiple exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and elements thereof may be replaced with equivalents without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the present disclosure without departing from its basic scope. Therefore, it is intended that the present invention as defined by the appended claims is not limited to any particular embodiment disclosed herein, but that the present invention will include all embodiments falling within the scope of the claims. In addition, in the drawings and the specification, exemplary embodiments have been disclosed, and although specific terms have been used, unless otherwise stated, they are used only in a general and descriptive sense, and not for the purpose of limitation. In addition, the use of the term "one" etc. does not indicate a limitation of quantity, but rather indicates that there is at least one referenced item, unless otherwise expressly stated. Reference numerals list

[0079] 100 Vehicle body panel assembly

[0080] 101 First structural element

[0081] 102 Second structural element

[0082] 103 Third structural element

[0083] 105 Sound Module

[0084] 106 Exciter

[0085] 107 lines

[0086] 108 Light Source

[0087] 109 Arrow

[0088] 110 Parts

[0089] 200 Transportation

[0090] 201 Vehicle body panel assembly

[0091] 203 Structural elements

[0092] 205 Radome

[0093] 207 Radar Antenna

[0094] 209 Cover

[0095] 211 Graphic Design

[0096] 213 Graphic Design

[0097] 215 Cover lens for LiDAR

[0098] 217 (Illuminated) symbol or radar radome

[0099] 219 Surface luminous part

[0100] 221 Heating unit

[0101] 223 Cover lens for lighting

[0102] 225 Light Source

[0103] 227 Lighting cover lens

[0104] 229 Car-to-Car Communication Module

[0105] 231 Sound Module

[0106] 300 Methods

[0107] 301 Forming steps

[0108] 303 Attachment Steps

Claims

1. A vehicle body panel assembly, wherein: The vehicle body panel assembly comprises: - at least one structural element (101, 102, 103); - a connection interface (104) for connecting the at least one structural element to a vehicle body; - at least one sound module (105), said at least one sound module comprising at least one exciter (106) coupled to said at least one structural element (101, 102, 103); - at least one light source (108), the at least one light source being coupled to the at least one structural element (101, 102, 103); and - at least one component (110) coupled to the at least one structural element (101, 102, 103) from the following list of components: at least one navigation unit, at least one communication unit (229), at least one antenna unit (205), at least one lighting unit, at least one signal light unit, at least one lighting unit, at least one heating unit (221), at least one cleaning unit, at least one design element (211), at least one lighting cover lens (209), at least one sensor cover lens (207), at least one sensor housing, at least one radar radome (205), at least one lidar radome, at least one security unit, at least one camera unit, at least one parking system unit, at least one symbol unit and at least one sensor unit, in particular at least one radar sensor unit, at least one lidar unit, at least one ultrasonic sensor unit, at least one parking sensor unit; The at least one exciter (106) is configured to cause the at least one structural element (101, 102, 103) to oscillate within a given frequency band.

2. The vehicle body panel assembly according to claim 1, wherein: The at least one actuator (106) is fixedly attached to the structural element (101, 102, 103).

3. The vehicle body panel assembly (100, 201) according to claim 1 or 2, wherein: The structural element (101, 102, 103) comprises a lens, in particular a front physical digital guard.

4. A vehicle body panel assembly (100, 201) according to any one of the preceding claims, wherein: The at least one sound module (105) comprises at least one sound source, which is configured to generate and / or amplify a sound signal to the at least one actuator (106), so that the sound signal is converted into sound waves by the at least one structural element (101, 102, 103).

5. The vehicle body panel assembly (100, 201) according to claim 4, wherein: The at least one sound source is attached to the structural element (101, 102, 103).

6. A vehicle body panel assembly (100, 201) according to any one of the preceding claims, wherein: The vehicle body panel assembly (100, 201) comprises as the at least one component at least one sensor unit, the at least one sensor unit being fixedly attached to the structural element (101, 102, 103) and at least partially integrated in the structural element (101, 102, 103).

7. A vehicle body panel assembly (100, 201) according to any one of the preceding claims, wherein: The structural elements (101, 102, 103) are profiled structures.

8. A vehicle body panel assembly (100, 201) according to any one of the preceding claims, wherein: The connection interface, the at least one sound module, the at least one light source (108) and the at least one component are at least partially integrated into the structural element (101, 102, 103).

9. A vehicle body panel assembly (100, 201) according to any one of the preceding claims, wherein: The connection interface (104) is configured to mechanically connect the vehicle body panel assembly (100, 201) to the front or rear or side or top of a vehicle (200).

10. The vehicle body panel assembly (100, 201) according to any of the preceding claims, further comprising a socket and / or a cable, in particular comprising exactly one socket and / or exactly one cable, for electrically connecting the vehicle body panel assembly (100, 201) to an external electrical component.

11. A vehicle (200) comprising at least one vehicle body panel assembly (100, 201) according to any one of claims 1 to 10.

12. A method (300) for manufacturing a vehicle body panel assembly (100, 201) according to any one of claims 1 to 10, the method (300) comprising: A forming process (301) for producing the structural element (101, 102, 103), in particular an inner mold forming process and / or an over mold forming process and / or a 2K forming process and / or a forming process of more than 2K; as well as An attaching process (303) of fixedly attaching the at least one sound module (105), the at least one light source (108) and the at least one component to the structural element (101, 102, 103).

13. The method according to claim 12, wherein: During the molding process, the at least one sound module, the at least one light source (108) and the at least one component are attached to the structural element (101, 102, 103) by at least partially covering them with molding material.

14. A method for manufacturing a vehicle (200), wherein: A vehicle body panel assembly (100, 201) according to any one of claims 1 to 10 is installed on a vehicle (200).

15. The method according to claim 14, wherein: The vehicle body panel assembly (100, 201) is installed on the vehicle (200) as a separate part.

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