Plastic-metal joining in the radar product for improved heat dissipation

Abstract

The invention relates to a measuring system (10), in particular a radar system (12), for measuring the distance between at least two objects and / or for measuring the speed of an object, with measuring electronics (14) for measuring a distance between the two objects and / or the speed of one object, with a heat sink (16), wherein the heat sink (16) has a receiving unit (18) and a cooling unit (22), wherein the measuring electronics (14) is arranged on a first side (20) of the receiving unit (18), and wherein the cooling unit (22) is designed to dissipate the heat generated during the operation of the measuring electronics (14) to the outside, and wherein the heat sink (16) has at least one joining area (24), and with a housing (26) for fluid-tight sealing of the measuring system (10), wherein the housing (26) has at least one joining web (28), wherein the joining web (28) of the housing (26) and the joining area (24) of the heat sink (16) are joined together, in particular inductively joined together.

Description

[0001] The invention relates to a measuring system with the features of independent claim 1 and a manufacturing method with the features of independent claim 14.

[0002] During operation, measuring systems, such as radar units, generate waste heat due to the integrated electronics. This heat must be dissipated from the measuring system during operation, i.e., while active, to ensure functionality. This is usually achieved by gluing or screwing a heat sink, along with thermal paste, into a housing. However, the cooling capacity of these heat sinks is limited by their design and enclosure, and is often insufficient for the ever-increasing power demands of modern measuring systems.

[0003] It is therefore an object of the present invention to overcome at least one of the disadvantages described above, at least partially. In particular, it is an object of the invention to provide a measuring system with increased and / or adjustable cooling capacity.

[0004] The foregoing problem is solved by a measuring system with the features of independent claim 1 and by a manufacturing process with the features of independent claim 14. Further features and details of the invention will become apparent from the dependent claims, the description, and the drawings. Features and details described in connection with the measuring system according to the invention naturally also apply in connection with the manufacturing process according to the invention, and vice versa, so that the disclosure of the individual aspects of the invention always makes, or can make, reciprocal references.

[0005] A first aspect of the invention is a measuring system, in particular a radar system, for measuring the distance between at least two objects and / or for measuring the speed of one object. The measuring system comprises measuring electronics for measuring the distance between the two objects and / or the speed of one object, as well as a heat sink, wherein the heat sink has a receiving unit and a cooling unit, the measuring electronics being arranged on a first side of the receiving unit. The cooling unit is designed to dissipate the heat generated during operation of the measuring electronics to the outside. The heat sink also has at least one joining area. Additionally, a housing is provided for fluid-tight sealing of the measuring system, wherein the housing has at least one joining surface, the joining surface of the housing and the joining area of ​​the heat sink being joined together, in particular inductively.

[0006] The direct connection of the heat sink to the housing allows heat to be transferred directly to the atmosphere via the heat sink, thus enabling ideal heat dissipation.

[0007] By joining the housing and the heat sink via the housing's connecting bridge and the heat sink's joining area, a strong and tight connection can be created, eliminating the need for additional sealing, screwing, or gluing of the two parts. This reduces the manufacturing costs of the measuring system while simultaneously shortening production cycle times. At the same time, the number of components required for the measuring system can also be reduced.

[0008] It is particularly advantageous if the course of the joining rib of the housing corresponds to the course of the joining area, thereby simplifying the positioning of the housing and the heat sink and ensuring a secure connection between the two.

[0009] Both the joining area and the joining bridge can be formed around the perimeter, thereby creating a fluid-tight joining connection between the housing and the heat sink.

[0010] A joining connection between the housing and the heat sink, or the joining of the housing and the heat sink, is understood to be a connection generated by heat, wherein the heat is advantageously generated by induction.

[0011] Within the scope of the invention, it can be advantageous for the joining area of ​​the heat sink to have a roughened structure.

[0012] The roughened structure increases the strength of the joint. During the joining process, heat is applied, causing one of the heated materials, particularly the housing material, to soften. This allows the softened material to move into the structure and solidify there.

[0013] The roughened structure can be introduced into the joining area of ​​the heat sink by laser or etching.

[0014] Within the scope of the invention, it is conceivable that the at least one joining web has a width of 0.5 to 10 mm, preferably 1 to 8 mm, more preferably 1.5 to 6 mm.

[0015] The width of the joining bridge can be selected depending on the size of the measuring system. It is advantageous if the width of the joining area is at least equal to the width of the joining bridge. It is conceivable that the width of the joining area is at least 1.0 times, preferably at least 1.2 times, and more preferably at least 1.5 times, the width of the joining bridge. The greater the width of the joining bridge, the larger the contact area between the joining bridge of the housing and the joining area of ​​the heat sink. A larger contact area increases the durability of the connection.

[0016] Within the scope of the invention, it may be provided that the receiving unit of the heat sink has a limiting rib, wherein the limiting rib is arranged circumferentially around the first side.

[0017] The limiting rib defines the first side of the recording unit and allows for easy positioning of the measuring electronics within the unit. At the same time, it increases the surface area for heat dissipation from the measuring electronics.

[0018] It is also conceivable that the housing is made of a thermoplastic material.

[0019] Plastics are very poor conductors of heat, which means that contact between the heat sink and the atmosphere allows for significantly better heat dissipation.

[0020] It is also conceivable that the heat sink is made of aluminum and / or steel.

[0021] This optimizes heat transfer from the measuring electronics, via the recording unit, to the cooling unit of the heat sink due to the good thermal conductivity of aluminum and steel. The cooling unit can be connected to an external heat sink, allowing for rapid heat dissipation.

[0022] The combination of a housing made of thermoplastic material and a heat sink made of aluminum and / or steel, whose cooling unit is located at least partially, preferably completely, outside the housing, is particularly advantageous, as it allows for optimal heat dissipation from the measuring electronics. This prevents overheating of the measuring system.

[0023] Within the scope of the invention, it is optionally possible that the cooling unit of the heat sink has at least two, preferably at least five, and more preferably at least ten, cooling fins.

[0024] Cooling fins increase the surface area in a simple way, allowing heat to be transferred from the measuring electronics to the heat sink via convection.

[0025] It is conceivable that the cooling fins could be exposed to a cool medium in order to increase convection.

[0026] The number of cooling fins depends on the heat to be dissipated and thus on the required cooling capacity, and can therefore be adapted to the requirements of the measuring electronics.

[0027] Furthermore, within the scope of the invention, it may be provided that the cooling fins have a thickness of 1 to 5 mm, preferably 1.5 to 4 mm, and more preferably 2 to 3 mm.

[0028] The thickness of the cooling fins can be adjusted to the required cooling capacity and depends on the number of cooling fins. The thickness should be chosen to ensure a uniform heat flow to the cooling fins, which can then be dissipated.

[0029] With regard to the present invention, it is conceivable that the cooling fins have a length of 4 to 20 mm, preferably 5 to 15 mm, more preferably 6 to 12 mm.

[0030] The length of the cooling fins influences the surface area for heat dissipation. Longer fins increase the heat dissipation rate, thus allowing the cooling capacity of the heat sink to be tailored to the cooling requirements of the measuring electronics.

[0031] Furthermore, it is conceivable that the cooling fins have a distance of 3 to 20 mm, preferably 4 to 18 mm, and more preferably 4 to 15 mm, from each other.

[0032] The distance is measured between the center axes of the cooling fins. This distance must be chosen to allow convection and ensure that the heat flow transported by the heat sink is optimally dissipated across the fin edges. It is advantageous if the distance between the cooling fins is at least twice, preferably at least three times, and more preferably at least four times, the width of the cooling fins.

[0033] Within the scope of the invention, it can be advantageous that the joining area of ​​the heat sink is provided on an upper side of the boundary web of the receiving unit and / or a cooling side wall of the boundary web and / or on a second side of the receiving unit, wherein the second side is arranged opposite the first side.

[0034] The arrangement of the joining area can be selected depending on the available installation space and thus on the available housing. This increases the flexibility of the measurement system design, as the cooling capacity of the heat sink, and therefore its size, can be adjusted depending on the size or performance of the measurement electronics. Since various positions of the joining area are available for connection to the housing, the dimensions of the heat sink, and thus also the dimensions of the cooling unit, can be easily adapted to the given structural features, while simultaneously maximizing its cooling capacity.

[0035] Within the scope of the invention, it is conceivable that the housing is a housing cover, wherein the housing cover has at least one joining web, and wherein the joining web is in joining connection with the joining area of ​​the top of the boundary web of the receiving unit and / or the cooling side wall of the boundary web.

[0036] This design of the measuring system is a simplified construction, which is primarily cost-efficient and space-saving. The housing cover can be placed or fitted onto the limiting rib to create the connection. Alternatively, the housing cover can be attached to the heat sink, resulting in an overlap between the housing cover and the cooling side wall.

[0037] Within the scope of the invention, it may be provided that the housing has a lower part and a housing cover connected to the lower part, wherein the lower part has a bottom with a recess for inserting the cooling unit of the heat sink and a circumferential side wall, wherein the at least one joining web is provided on the bottom of the lower part to join the joining web of the bottom with the joining area on the second side of the receiving unit of the heat sink, and / or wherein the at least one joining web is provided on the circumferential side wall of the lower part to join the joining web of the side wall with the joining area of ​​the side wall of the limiting web.

[0038] This increases flexibility, allowing the housing to accommodate additional components without affecting the cooling capacity for the measuring electronics. Here too, the position of the joining area on the heat sink, or the joining surface on the housing, can be selected depending on the design of the heat sink, the available installation space, and / or the available housing.

[0039] It would also be conceivable to insert the heat sink into an existing housing to save space.

[0040] Furthermore, it is conceivable that the heat sink can be replaced or expanded depending on heat generation in order to maintain or increase the cooling capacity for the measuring electronics. This is particularly advantageous for longer operating times of the measuring electronics, as it is not necessary to replace the entire measuring system, but only the heat sink.

[0041] A second aspect of the invention is a manufacturing method for producing a measuring system according to the first aspect of the invention, comprising the following steps: - Providing the heat sink with a receiving unit and a cooling unit, wherein the receiving unit has a joining area, - Providing a housing with a joining bridge, - Positioning the heat sink in or on the housing so that the mounting flange of the housing and the mounting area of ​​the heat sink are in contact, - Locally introducing heat into the heat sink in the area of ​​the joining area and into the housing in the area of ​​the joining bridge to join the housing and the heat sink together.

[0042] The direct connection between the housing and the heat sink allows the waste heat to be dissipated directly via the heat sink. This is particularly advantageous when the housing is made of thermoplastic material and the heat sink is made of aluminum and / or steel.

[0043] By joining the components through local heating, the measuring system can be manufactured cost-effectively and with shorter cycle times.

[0044] It is also conceivable that the heat is introduced via induction.

[0045] Alternatively or additionally, it is conceivable that the housing could be connected to the heat sink using a laser welding process.

[0046] This allows for simple local heating of the joining surface and the joining area.

[0047] In addition, thermal joining by induction, due to the possible reverse process or "disassembly", also allows the development of innovative repair concepts and a pure material separation at the end of the component's life.

[0048] The advantages described in detail for the measuring system according to the first aspect of the invention also apply to the manufacturing process for producing a measuring system according to the second aspect of the invention.

[0049] Further advantages, features, and details of the invention will become apparent from the following description, which describes several embodiments of the invention in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential to the invention individually or in any combination. The invention is illustrated in the following figures: Fig. 1 a schematic representation of a measuring system in a first embodiment, Fig. 2 a schematic representation of a measuring system in a second embodiment, and Fig. 3. A schematic representation of a manufacturing process.

[0050] In Fig. 1 and Fig. Figure 2 shows a measuring system 10, in particular a radar system 12, for measuring the distance between at least two objects and / or for measuring the speed of one object. The measuring system 10 comprises measuring electronics 14 for measuring a distance between the two objects and / or the speed of one object, a heat sink 16, and a housing 26 for fluid-tight sealing of the measuring system 10. The heat sink 16 comprises a receiving unit 18 and a cooling unit 22, wherein the measuring electronics 14 are arranged on a first side 20 of the receiving unit 18, and wherein the cooling unit 22 is designed to dissipate the heat generated during the operation of the measuring electronics 14 to the outside. The heat sink 16 has at least one joining area 24 and the housing 26 has at least one joining web 28, wherein the joining web 28 of the housing 26 and the joining area 24 of the heat sink 16 are joined together, in particular inductively joined together.

[0051] In both embodiments, the housing 26 is made of a thermoplastic material and the heat sink 16 is made of aluminum. Additionally or alternatively, the heat sink 16 can also be made of steel.

[0052] During the joining process, heat is introduced by induction, causing at least some of the thermoplastic material of the housing 26 to liquefy. To utilize this effect for a secure connection, the joining area 24 of the heat sink 16 has a roughened structure. This allows the partially liquefied plastic to flow into the structure, thus increasing the contact area and improving durability.

[0053] To ensure the durability of the connection, at least one joining web 28 has a width B_FS of 0.5 to 10 mm. With a minimum width B_FS of 0.5 mm, the connection can at least be guaranteed; this is particularly suitable for small measuring systems 10. In the present embodiments, the width ranges from 1 to 8 mm.

[0054] For the positioning of the measuring electronics 14, the receiving unit 18 of the heat sink 16 has a limiting web 30, wherein the limiting web 30 is arranged around the first side 20.

[0055] To optimize the cooling or the dissipation of heat from the measuring electronics 14, the cooling unit 22 of the heat sink 16 has at least two, preferably at least five, and more preferably at least ten, cooling fins 32.

[0056] The cooling fins 32 have a thickness D_KR of 1 to 5 mm and a length L_KR of 4 to 20 mm. The cooling fins 32 are spaced A_KR apart from each other at a distance of 3 to 20 mm. This distance A_KR is measured from a central axis 50 of the cooling fins 32. In the present embodiments, the distance A_KR of the cooling fins 32 corresponds to the Fig. 1 and Fig. 2 at least twice the width B_FS of the cooling fins 32.

[0057] Depending on the design of the measuring system 10 and also depending on the available installation space, the joining area 24 of the heat sink 16, or the joining web 28 of the housing 26, can be provided in different positions. The joining area 24 of the heat sink 16 can be located on a top surface 34 of the limiting web 30 of the receiving unit 18, and / or on a cooling side wall 36 of the limiting web 30, and / or on a second side 38 of the receiving unit 18, wherein the second side 38 is arranged opposite the first side 20.

[0058] In Fig. In 1, the housing 26 is a housing cover 40, wherein the housing cover 40 has at least one joining web 28. Here, the joining area 24 of the heat sink 16 is provided on the upper side 34 of the limiting web 30 of the receiving unit 18, so that the corresponding joining web 28 of the housing cover 40 is joined to it.

[0059] It is also conceivable that the joining area 24 on the cooling side wall 36 of the limiting web 30 is intended for the formation of the joining connection.

[0060] In Fig. The housing 26 is divided into two parts and comprises a lower part 42 and a housing cover 40 connected to the lower part 42. The lower part 42 has a base 44 with a recess 46 for inserting the cooling unit 22 of the heat sink 16 and a surrounding side wall 48. At least one joining element 28 is provided on the base 44 of the lower part 42 to connect the joining element 28 of the base 44 with the joining area 24 on the second side 38 of the receiving unit 18 of the heat sink 16.

[0061] In this embodiment, it is conceivable, but not shown here, that at least one joining web 28 is provided on the circumferential side wall 48 of the lower part 42 in order to join the joining web 28 of the side wall 48 with the joining area 24 of the side wall 48 of the limiting web 30.

[0062] In Fig. 3 is a manufacturing process 100 for manufacturing a measuring system 10 of one of the preceding Fig. 1 or Fig. Figure 2 shows the manufacturing process 100, which comprises the following steps: - Providing 110 of the heat sink 16 with a receiving unit 18 and a cooling unit 22, wherein the receiving unit 18 has a joining area 24, - Providing 120 of a housing 26 with a joining bridge 28, - Position 130 of the heat sink 16 in or on the housing 26 so that the joining web 28 of the housing 26 and the joining area 24 of the heat sink 16 are adjacent to each other, - local introduction 140 of heat into the heat sink 16 by means of induction in the area of ​​the joining area 24 and into the housing 26 in the area of ​​the joining bridge 28, in order to join the housing 26 and the heat sink 16 together. List of reference symbols 10 measuring system 12 radar systems 14 Measuring electronics 16 heat sinks 18 recording units 20 first page 22 cooling units 24 joining area 26 cases 28 Joining bridge 30 Boundary walkway 32 cooling fins 34 Top 36 Cooling side wall 38 second page 40 Housing covers 42 Lower part 44 Floor 46 recess 48 side wall 50 Center axis 100 manufacturing processes 110 Providing the heat sink 120 Providing the enclosure 130 Positioning 140 Bring in B_FS width D_KR Thickness L_KR length A_KR distance

Claims

[1] Measuring system (10), in particular radar system (12), for measuring the distance between at least two objects and / or for measuring the speed of an object, with measuring electronics (14) for measuring a distance between the two objects and / or the speed of one object, with a heat sink (16), wherein the heat sink (16) has a receiving unit (18) and a cooling unit (22), wherein the measuring electronics (14) is arranged on a first side (20) of the receiving unit (18), and wherein the cooling unit (22) is designed to dissipate the heat generated during operation of the measuring electronics (14) to the outside, and wherein the heat sink (16) has at least one joining area (24), and with a housing (26) for fluid-tight sealing of the measuring system (10), wherein the housing (26) has at least one joining web (28), wherein the joining web (28) of the housing (26) and the joining region (24) of the heat sink (16) are joined together, in particular joined together inductively. [2] Measuring system (10) according to claim 1, characterized by that the joining area (24) of the heat sink (16) has a roughened structure. [3] Measuring system (10) according to claim 1 or 2, characterized by that the at least one joining web (28) has a width (B_FS) of 0.5 to 10 mm, preferably 1 to 8 mm, more preferably 1.5 to 6 mm. [4] Measuring system (10) according to one of the preceding claims, characterized by that the receiving unit (18) of the heat sink (16) has a limiting web (30), wherein the limiting web (30) is arranged circumferentially around the first side (20). [5] Measuring system (10) according to one of the preceding claims, characterized bythat the housing (26) comprises a thermoplastic material. [6] Measuring system (10) according to one of the preceding claims, characterized by that the heat sink (16) comprises aluminum and / or steel. [7] Measuring system (10) according to one of the preceding claims, characterized by that the cooling unit (22) of the heat sink (16) has at least two, preferably at least five, more preferably at least ten, cooling fins (32). [8] Measuring system (10) according to claim 7, characterized by that the cooling fins (32) have a thickness (D_KR) of 1 to 5 mm, preferably 1.5 to 4 mm, more preferably 2 to 3 mm. [9] Measuring system (10) according to claim 7 or 8, characterized by that the cooling fins (32) have a length (L_KR) of 4 to 20 mm, preferably 5 to 15 mm, more preferably 6 to 12 mm. [10] Measuring system (10) according to one of claims 7 to 9, characterized bythat the cooling fins (32) have a distance (A_KR) of 3 to 20 mm, preferably 4 to 18 mm, more preferably 4 to 15 mm, from one another. [11] Measuring system (10) according to one of the preceding claims, characterized by that the joining region (24) of the cooling body (16) is provided on an upper side (34) of the boundary web (30) of the receiving unit (18) and / or a cooling side wall (36) of the boundary web (30) and / or on a second side (38) of the receiving unit (18), wherein the second side (38) is arranged opposite the first side (20). [12] Measuring system (10) according to one of the preceding claims, characterized by that the housing (26) is a housing cover (40), wherein the housing cover (40) has the at least one joining web (28), and wherein the joining web (28) is in joining connection with the joining region (24) of the upper side (34) of the limiting web (30) of the receiving unit (18) and / or the cooling side wall (36) of the limiting web (30). [13] Measuring system (10) according to one of the preceding claims, characterized by that the housing (26) has a lower part (42) and a housing cover (40) connected to the lower part (42), wherein the lower part (42) has a bottom (44) with a recess (46) for the insertion of the cooling unit (22) of the heat sink (16) and a circumferential side wall (48), wherein the at least one joining web (28) is provided on the bottom (44) of the lower part (42) in order to join the joining web (28) of the bottom (44) to the joining region (24) on the second side (38) of the receiving unit (18) of the heat sink (16), and / or wherein the at least one joining web (28) is provided on the circumferential side wall (48) of the lower part (42) in order to join the joining web (28) of the side wall (48) to the joining region (24) of the side wall (48) of the boundary web (30). [14] Manufacturing method (100) for producing a measuring system (10) according to one of the preceding claims, comprising the following steps: - Providing (110) the heat sink (16) with a receiving unit (18) and a cooling unit (22), wherein the receiving unit (18) has a joining area (24), - providing (120) a housing (26) with a joining web (28), - positioning (130) the heat sink (16) in or on the housing (26) so that the joining web (28) of the housing (26) and the joining area (24) of the heat sink (16) lie against each other, - local introduction (140) of heat into the heat sink (16) in the region of the joining area (24) and into the housing (26) in the region of the joining web (28) in order to join the housing (26) and the heat sink (16) together. [15] Manufacturing method (100) according to claim 14, characterized by that the heat is introduced by induction.

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