Sensor module with environmental sensor and heating device

Abstract

Sensor module (18) for a motor vehicle (1000), comprising: a cover (20), a see-through area (24) arranged on the cover (20), an environment sensor (22) which can detect a vehicle environment through the see-through area (24), a heating device (26) which is provided on the see-through area (24) and is designed to defrost and / or dehumidify the see-through area (24), and at least one fastening element (30, 32, 46) which is designed to penetrate the see-through area (24) and the heating device (26) at least partially in a self-tapping or self-drilling manner, and via which the heating device (26) can be electrically contacted with an electrical energy source (33).

Description

[0001] The invention relates to a sensor module, in particular a roof sensor module (RSM) for a passenger car. Furthermore, the invention relates to a vehicle roof with such a sensor module. The invention also relates to a motor vehicle with such a sensor module and / or such a vehicle roof.

[0002] Vehicle roofs are known in practice. A vehicle roof can, for example, be designed as a roof sensor module that can be attached as a separate structural unit to a passenger car body forming a vehicle shell. As an interface to the vehicle roof, the vehicle body comprises roof beams, which can be designed as longitudinal beams and / or transverse beams and represent a support structure on the vehicle body. The vehicle roof comprises a roof skin that forms an outer visible surface and has sensor viewing areas through which environmental sensors, which are arranged beneath the roof skin and serve to detect the vehicle's surroundings, can detect the vehicle's surroundings.

[0003] Autonomous or semi-autonomous vehicles, for example, include a roof designed as a sensor roof module or roof sensor module (RSM), which is equipped with a multitude of environmental sensors. The environmental sensors, which are integrated in a dry area into the vehicle roof, which is particularly designed as a roof sensor module, and which are designed, for example, as lidar sensors and / or radar sensors and / or cameras, record the environment around the vehicle and provide the corresponding measurement signals to the control electronics of the respective vehicle, so that the respective traffic situation can be determined and the driving behavior of the respective vehicle can be adapted to this traffic situation.

[0004] The integration of environmental sensors into autonomous vehicles is proving advantageous for the development of modern vehicle systems. Placing these environmental sensors in the roof area of ​​the vehicle has proven particularly advantageous for ensuring optimal visibility and functionality.

[0005] A known problem with this type of integration, however, is the icing and / or fogging of a viewing area through which an environment sensor looks to detect the vehicle's surroundings. These viewing areas can be attached directly to the environment sensor or to an additional cover. To counteract this problem, heating or defogging elements are used. However, connecting these heating elements to the vehicle's wiring harness often proves very complex, which complicates integration into the sensor modules. Furthermore, the adaptability of the heating elements in combination with additional covers is limited. This presents engineers and developers with challenges in developing efficient and reliable sensor solutions for autonomous vehicles.

[0006] A sensor module for installation on a motor vehicle is known from DE 10 2022 115 973 A1. The sensor module comprises an environment sensor and a heating device with a heating area integrated between a first and a second viewing area for the environment sensor.

[0007] An electrical connection device for plastic discs is known from US 2008 / 0268672 A1. The connection device comprises a screw that engages the plastic disc.

[0008] DE 101 22 798 C1 discloses a combined plug-in and screw connection between two components. The screw connection comprises a self-tapping screw that is screwed into the material of the first component.

[0009] It is an object of the invention to provide an improved sensor module.

[0010] The problem is solved by a sensor module having the features of patent claim 1.

[0011] Advantageous embodiments of the invention are the subject of the dependent claims. The scope of the invention includes all combinations of at least two features disclosed in the description, the claims, and / or the figures. It is understood, in particular, that customary linguistic transformations and / or analogous replacements of respective terms within the scope of common linguistic practice, in particular the use of synonyms supported by generally accepted linguistic literature, are encompassed by the present disclosure content without being explicitly mentioned in their respective formulation.

[0012] In a preferred aspect, a sensor module for a motor vehicle is proposed. The sensor module comprises a cover, a see-through area arranged directly or indirectly on the cover, an environment sensor capable of detecting the vehicle's surroundings through the see-through area, a heating device provided on the see-through area and configured to defrost and / or dehumidify the see-through area, and at least one fastening element configured to self-cut or self-drill through the see-through area and the heating device, at least partially or in a sub-area of ​​the see-through area, and via which the heating device can be electrically contacted with an electrical energy source.

[0013] The at least one fastening element is preferably arranged in an edge region of the see-through area.

[0014] Self-tapping fasteners are fasteners designed to cut their own thread when screwed into a material (usually metal or plastic). These fasteners have sharp edges or cutting wings, for example, that remove material when screwed in and form a thread into the material. These fasteners preferably do not require a pre-drilled centering hole, but this may be preferred in certain circumstances.

[0015] Self-drilling fasteners are fasteners that have a drill bit and / or self-tapping properties. They can be screwed directly into the material (usually metal or plastic) without pre-drilling. The drill bit of the screw penetrates the material and creates a hole, while the subsequent threads form the material and cut a thread. These fasteners thus combine drilling and cutting in a single step and are particularly useful for applications where time and efficiency are critical. Fasteners that are forced through a material by the sheer application of force, without the need for any rotational movement of the fastener, are also referred to as self-drilling. The material, for example the see-through area and the heating element, is penetrated by the fastener in such a way that the material is perforated.

[0016] This sensor module enables an effective and secure electrical or electronic connection of the heating system. Furthermore, the connection to a vehicle's wiring harness or an electrical connection leading to an electrical power source can be improved. The sensor module enhances the overall design and styling of the vehicle. Furthermore, the sensor module can improve the layout and minimize installation space. Furthermore, this sensor module can easily accommodate additional mechanical components in the viewing area. Overall, a reduction in installation space, weight, and costs can be achieved.

[0017] In a further aspect, it is proposed that the heating device comprises at least one collecting line, wherein the fastening element penetrates the at least one collecting line in a self-cutting or self-drilling manner, so that the fastening element electrically contacts the at least one collecting line.

[0018] The heating device preferably comprises a plurality of conductor tracks that are interconnected by at least one bus bar, in particular connected in series. The plurality of conductor tracks and the bus bar can preferably be vapor-deposited, painted, or applied to the see-through area. The plurality of conductor tracks and the bus bar can also be provided with electrical conductivity, for example, in paint or varnish, or even as thin metal tracks.

[0019] In a further aspect, it is proposed that the see-through area has at least one material-weakened section, and wherein the at least one fastening element penetrates the material-weakened section in a self-tapping or self-drilling manner.

[0020] The material-weakened section can, for example, be provided as a type of blind hole. This section preferably serves to simplify the insertion of the fastening element and to center the fastening element relative to the viewing area during insertion. The section can, for example, be provided by removing material. The section preferably forms a type of trough or depression into which the fastening element can be inserted. In this way, the fastening element can be attached with less force.

[0021] In a further aspect, it is proposed that the fastening element comprises a screw, wherein the screw penetrates the see-through area and the heating device at least partially in a self-tapping manner, and / or wherein the fastening element comprises a bolt, wherein the bolt penetrates the see-through area and the heating device at least partially in a self-tapping manner.

[0022] Self-tapping screws are preferably screws that are designed to cut their own thread when screwed into a material (usually metal or plastic). These screws have sharp edges or cutting wings that remove material as they are screwed in and form a thread into the material. They usually require a pre-drilled hole into which they can cut themselves. Self-drilling screws are preferably screws that have both a drill bit and self-tapping properties. They can be screwed directly into the material (usually metal or plastic), preferably without pre-drilling. The drill bit of the screw preferably penetrates the material and creates a hole, while the subsequent threads form the material and cut a thread.These screws combine drilling and cutting in a single step and are particularly practical for applications where time and efficiency are critical. Similar designs are preferred for bolts.

[0023] Furthermore, it is also possible to push the bolt through the viewing area in a linear movement orthogonal to the viewing area without a rotational movement.

[0024] In a further aspect, it is proposed that the fastening element protrudes from the see-through area and is designed to accommodate an electrical wiring via which the heating device can be electrically contacted with the electrical energy source.

[0025] Preferably, the fastening element protrudes from the see-through area on an inner side. This allows additional electrical devices such as eyelets, washers, and / or at least one nut to be attached to the fastening element.

[0026] In a further aspect, it is proposed that the see-through area is arranged on the cover via the at least one fastening element, preferably molded or injected or glued.

[0027] The see-through area can, in principle, also be integrated directly into the cover. The cover can, for example, be manufactured using an injection molding process. In this case, the see-through area can, for example, be arranged on the cover using the injection molding material. In principle, the see-through area can also be glued to the cover. The cover can, for example, have a window into which the see-through area is inserted. There is preferably a seal between the cover and the see-through area so that no moisture can penetrate between the cover and the see-through area into the interior of the sensor module. This seal can be integral or provided by an additional seal.

[0028] In a further aspect, it is proposed that the cover is designed as an injection-molded component, and wherein the at least one fastening element and preferably an edge region of the see-through region is / are over-molded by the cover.

[0029] The cover can generally be designed as a 1-component or 2-component (2K) injection-molded component. The cover can at least partially cover the fastening element and preferably the edge region of the see-through area, so that an integral arrangement of the see-through area on the cover is possible. This also has particular advantages in terms of design. In this way, the fastening elements cannot be seen from the outside, as they are concealed by the cover. The cover can preferably be made of a material that is opaque to the human eye. The see-through area can preferably also be made of a material that is opaque to the human eye but transparent to the environmental sensor.

[0030] In a further aspect, it is proposed that the sensor module further comprises a holder, wherein the see-through area is arranged on the holder via the at least one fastening element.

[0031] The see-through area does not necessarily have to be attached directly to the cover. Alternatively, the sensor module can also have a holder via which the see-through area is attached to the sensor module. In such a case, the cover can, for example, only rest against the see-through area in an edge region of the see-through area. It is preferred that the cover is sealed off from the see-through area. This can be achieved, for example, by an additional seal. The holder can, for example, be connected to a structural component of the motor vehicle or the sensor module. The holder can, for example, have an opening or hole through which the fastening element extends for attachment to the holder. Alternatively, however, the fastening element can also perforate the holder and thus be attached to the holder.

[0032] The present invention also relates to a vehicle roof of a motor vehicle, comprising at least one sensor module according to any embodiment.

[0033] A preferred embodiment of the vehicle roof is designed as a roof sensor module. Such a roof sensor module forms an integrated unit that accommodates components required for autonomous or semi-autonomous driving of the vehicle in question. The roof sensor module, which can therefore integrate a multitude of functional elements, thus represents a compact unit that is connected by a vehicle manufacturer to a vehicle body or a vehicle shell that includes roof pillars, such as roof side pillars and / or longitudinal roof pillars. The vehicle roof designed as a roof sensor module thus represents a sensor roof module or roof sensor module (RSM), which enables autonomous or semi-autonomous driving of the vehicle in question.

[0034] A motor vehicle equipped with such a vehicle roof and designed as an autonomous vehicle drives independently in autonomous driving mode, at least without significant driver intervention. In a semi-autonomous driving mode, the vehicle roof according to the invention forms, for example, part of a driver assistance system.

[0035] The vehicle roof may be provided with a transparent fixed roof section and / or a roof opening system for a roof opening.

[0036] In particular, the vehicle roof at least partially forms the roof of a passenger car. However, it can also be the roof of a commercial vehicle, for example, a delivery van, a bus, an autonomous minibus (a so-called people mover), or even a truck tractor.

[0037] The present invention also claims a motor vehicle comprising a sensor module and / or a vehicle roof of the type described above. The vehicle roof preferably forms a roof sensor module (RSM), which can be arranged as a pre-assembled unit on a vehicle body of the motor vehicle. In other words, in particular, a vehicle body of the motor vehicle can be provided with a prefabricated or pre-assembled roof sensor module, which is designed as a sensor roof module or roof sensor module.

[0038] It is understood that the embodiments and examples mentioned above and those to be explained below can be implemented not only individually, but also in any combination with one another without departing from the scope of the present invention. It is also understood that the embodiments and examples mentioned above and those to be explained below relate in an equivalent or at least similar manner to all embodiments of the invention, without each being mentioned separately.

[0039] Embodiments of the invention are shown schematically in the drawings and are explained below by way of example. Fig. 1 shows a schematic representation of a vehicle roof with a sensor module; Fig. 2 shows an embodiment of a sensor module; Fig. 3 shows an embodiment of a sensor module; Fig. 4 shows an embodiment of a sensor module; Fig. 5 shows a step-by-step contacting of a heating device of a sensor module; Fig. 6 shows a step-by-step contacting of a heating device of a sensor module.

[0040] Fig. 1 schematically shows a motor vehicle 1000 having a vehicle body 1002. Furthermore, the motor vehicle 1000 has a roof sensor module 10, which is arranged as a structural unit on the vehicle body 1002 and, at least in some regions, forms a vehicle roof 100 of the motor vehicle 1000. The roof sensor module 10 can be provided as a pre-assembled unit.

[0041] In alternative embodiments, the vehicle roof 100 may also be a vehicle roof that is not configured as a roof sensor module. Thus, all embodiments also refer to such a vehicle roof 100.

[0042] The roof sensor module 10 comprises a surface component 12, which at least partially forms a roof skin 14 of the vehicle roof 100. The roof sensor module 10 comprises Fig. 1 shows a fixed roof element 16 that forms an at least partially transparent area of ​​the vehicle roof 100. In other or additional embodiments, the roof sensor module 10 may have a roof opening system that includes a cover element that can be displaced to selectively open or close a roof opening.

[0043] The roof sensor module 10 or the vehicle roof 100 has a sensor module 18. The sensor module 18 is arranged in a front region, viewed in a vehicle longitudinal direction x. The vehicle longitudinal direction x is orthogonal to a vehicle width direction y. The sensor module 18 has a cover 20. Furthermore, the sensor module 18 has at least one environment sensor 22 for detecting the vehicle's surroundings. The environment sensor 22 is configured to detect the vehicle's surroundings via a viewing area 24. In this case, the viewing area 24 is arranged on the cover 20. The environment sensor 22 can be a lidar sensor and / or a camera and / or a radar sensor and / or an ultrasonic sensor and / or a multi-camera sensor. Other sensors are also conceivable.

[0044] The environment sensor 22 can be arranged in a sensor housing. The cover 20 can also be a part of this sensor housing or form the sensor housing. The environment sensor 22 can be arranged below the cover 20 or covered by the cover 20. The see-through area 24 can be provided as a window in an opening in the cover 20 (not shown in detail). The see-through area 24 can be provided integrally in the cover 20 or arranged separately therein. The see-through area 24 can also be provided in the sensor housing.

[0045] Fig. 2 shows an embodiment of the sensor module 18 in which the see-through area 24 is arranged directly on the cover 20. The sensor module 18 has a heating device 26, which in this case is arranged on an inner side of the see-through area 24, viewed in a viewing direction of the environment sensor 22. The heating device 26 can, for example, be sprayed or glued or vapor-deposited or painted onto the see-through area 24, or laminated to the see-through area 24 by means of a carrier film. The heating device 26 comprises electrically conductive conductor tracks. The heating device 26 can, for example, be formed by means of an electrically conductive paint or varnish or by metal lines. The heating device 26 preferably has a busbar 28, via which the conductor tracks are collectively contacted.

[0046] The sensor module 18 further comprises at least one fastening element 30. According to Fig. 2, the fastening element 30 is a bolt 32. The bolt 32 penetrates the viewing area 24 and the heating device 26 at least partially self-drilling.

[0047] The heating device 26 can be electrically contacted with an electrical energy source 33 via the bolt 32. To contact the heating device 26, the bolt 32 was forced through the see-through area 24 and the heating device 26 mounted thereon, without a through hole having previously been present in the see-through area 24 or the heating device 26. Upon penetrating, the bolt 32 deforms the heating device 26, thereby creating a very good electrical connection between the bolt 32 and the heating device 26. In this case, the bolt 32 contacts the busbar 28 of the heating device 26.

[0048] According to Fig. 2, the cover 20 is formed as an injection-molded component 34. The at least one fastening element 30 or the bolts 32, as well as an edge region of the see-through area 24, are overmolded by the cover 20. Thus, the see-through area 24 can be attached to the cover 20 directly via the at least one fastening element 30.

[0049] For mechanical fastening of the bolt 32, this is according to Fig. 2 is secured with a nut 36. Furthermore, for electrically connecting the heating device 26 to the energy source 33, an optional washer 38, a connection eyelet 40 of an electrical wiring 42, and another optional washer 44 are provided between the heating device 26 and the nut 36 on the bolt 32. The nut 36 secures the bolt 32 and thereby contacts the washer 38, the connection eyelet 40 of the electrical wiring 42, and the washer 44 with the heating device 26. The wiring 42 is connected to the energy source 33, so that the heating device 26 can be supplied with electrical energy via the wiring 42, the connection eyelet 40, and the washer 38. The energy source can also simultaneously form a control device for the heating device 26, which, for example, receives further sensor signals and controls the heating device based thereon.

[0050] Fig. 3 differs from Fig. 2 in that a screw 46 is used as the fastening element 30 to electrically contact the heating device 26 or the bus bar 28. The screw 46 penetrates the see-through area 24 and the heating device 26 or the bus bar 28 at least partially in a self-tapping manner, so that a very good electrical contact is established. Furthermore, the sensor module 18 according to Fig. 3 has a holder 48. The see-through area 24 is arranged indirectly on the cover 20 by the holder 48. The holder 48 can be arranged, for example, on the sensor housing or another structural component. The see-through area 24 is held on the holder 48 by at least one screw 46. The heating device 26 is located according to Fig. 3 directly onto the holder 48. The screw 46 extends through the holder 48 to secure the viewing area 24 to the holder 48 in a force-fitting and form-fitting manner. The washer 38, the connection eyelet 40, and the washer 44 are again layered behind the holder 48 and secured by the nut 36.

[0051] Fig. 4 shows a schematic view of a sensor module 18 in which the heating device 26 is electrically contacted by the at least one screw 46. In addition, the Fig. 4 shown sensor module 18 preferably corresponds to the embodiments Fig. 2 or Fig. 3.

[0052] Fig. 5 shows a step-by-step process for contacting the heating device 26. According to Fig. 5, in a first step S1, the see-through area 24 is provided together with the heating device 26 provided thereon and to be contacted. In a step S2, the fastening element 30 is then forced through the see-through area 24 and the heating device 26, at least partially self-tapping or self-drilling, in order to electrically contact the heating device 26. Then, in a step S3, the washer 38, the connection eyelet 40, and the washer 44 are sequentially layered and countered by the nut 36.

[0053] Fig. 6 shows a step-by-step process for contacting the heating device 26. The see-through area 24 has at least one material-weakened section 50. According to Fig.6, in a first step S1, the see-through area 24 is provided together with the heating device 26 provided thereon and to be contacted. In a step S2, the fastening element 30 is then forced through the at least one material-weakened section 50 of the see-through area 24 and the heating device 26, at least partially self-tapping or self-drilling, in order to electrically contact the heating device 26. Then, in a step S3, the washer 38, the connection eyelet 40, and the washer 44 are sequentially layered and countered by the nut 36. List of reference symbols 10 roof sensor module 12 Surface component 14 Roof skin 16 fixed roof element 18 Sensor module 20 Cover 22 Environment sensor 24 viewing area 26 Heating device 28 collection managers 30 Fastening element 32 bolts 33 Energy source 34 injection-molded component 36 mother 38 Washer 40 connection eyelet 42 Cabling 44 Washer 46 Screw 48 holders 50 material-weakened section 100 vehicle roof 1000 motor vehicles 1002 Vehicle body x Vehicle longitudinal direction y vehicle width direction

Claims

[1] Sensor module (18) for a motor vehicle (1000) comprising: a cover (20), a see-through area (24) arranged on the cover (20), an environment sensor (22) which can detect a vehicle environment through the see-through area (24), a heating device (26) which is provided on the see-through area (24) and is designed to defrost and / or dehumidify the see-through area (24), and at least one fastening element (30, 32, 46) which is designed to penetrate the see-through area (24) and the heating device (26) at least partially in a self-tapping or self-drilling manner, and via which the heating device (26) can be electrically contacted with an electrical energy source (33). [2] Sensor module (18) according to claim 1, wherein the heating device (26) comprises at least one collecting line (28), wherein the fastening element (30, 32, 46) penetrates the at least one collecting line (28) in a self-cutting or self-drilling manner, so that the fastening element (30, 32, 46) electrically contacts the at least one collecting line (28). [3] Sensor module according to claim 1 or 2, wherein the see-through area (24) has at least one material-weakened section (50), and wherein the at least one fastening element (30, 32, 46) penetrates the material-weakened section (50) in a self-cutting or self-drilling manner. [4] Sensor module (18) according to one of the preceding claims, wherein the fastening element (30) comprises a screw (46), wherein the screw (46) penetrates the see-through area (24) and the heating device (26) at least partially in a self-tapping manner, and / or wherein the fastening element (30) comprises a bolt (32), wherein the bolt (32) penetrates the see-through area (24) and the heating device (26) at least partially in a self-tapping manner. [5] Sensor module (18) according to one of the preceding claims, wherein the fastening element (30, 32, 46) protrudes from the see-through area (24) and is designed to receive an electrical wiring (42) via which the heating device (26) can be electrically contacted with the electrical energy source (33). [6] Sensor module (18) according to one of the preceding claims, wherein the see-through area (24) is arranged on the cover (20) via the at least one fastening element (30, 32, 46), preferably injection-molded or glued. [7] Sensor module (18) according to claim 6, wherein the cover (20) is designed as an injection-molded component (34), and wherein the at least one fastening element (30, 32, 46) and preferably an edge region of the see-through region (24) is / are over-molded by the cover (20). [8] Sensor module (18) according to one of claims 1 to 5, wherein the sensor module (18) further comprises a holder (48), wherein the see-through area (24) is arranged on the holder (20) via the at least one fastening element (30, 32, 46). [9] Vehicle roof (100) of a motor vehicle (1000), comprising at least one sensor module (18) according to one of claims 1 to 8. [10] Motor vehicle (1000) comprising a sensor module (18) according to one of claims 1 to 8 and / or a vehicle roof (100) according to claim 9, wherein the vehicle roof (100) forms a roof sensor module (10) which can be arranged as a pre-assembled unit on a vehicle body (1002) of the motor vehicle (1000).

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