Scanner module for vehicle add-on parts

Abstract

The invention relates to a scanner module (1), in particular a lidar scanner module, for a vehicle add-on part (2) at least comprising a scanner (3), preferably a lidar scanner, and an external cover (4) with a passage region (D), wherein furthermore the external cover (4), as outer endpiece, is integrable in or a replacement of the vehicle add-on part (2), characterized in that at least one optical means (5) comprising a prism arrangement (5b) is arranged in the beam path of the scanner between the scanner (3) and the external cover (4). The invention also encompasses a method for producing such a scanner module (1).

Description

[0001] Scanner module for vehicle attachments

[0002] The invention relates to a scanner module, in particular a LiDaR scanner module for vehicle attachments with improved properties, and a method for its production.

[0003] Today's, and especially future, luxury and mid-size vehicles are equipped with a variety of driver assistance systems. These include, for example, optical cameras, mid-range and long-range radar systems, ultrasonic sensors, rain sensors, daylight sensors, backlight sensors, and Light Detection and Ranging (LiDaR). These systems can also be summarized under the term ADAS (Advanced Driver Assist Systems). They are generally used for traffic monitoring and can, for example, recognize road signs or determine the position and speed of objects outside the vehicle, such as other road users or obstacles in the roadway. Currently, optical cameras or radar systems are primarily used for this purpose. The use of cameras has the disadvantage that object detection is heavily dependent on external environmental influences, in particular the prevailing lighting and weather conditions.The use of radar systems for.

[0004] Traffic monitoring is virtually independent of light and weather conditions, but the precision of radar systems is currently insufficient for proper object detection. LiDaR (Light Detection and Ranging) systems have proven advantageous in this regard. They use laser pulses with, for example, a wavelength in the infrared range to scan the surroundings point by point and create an image of the environment. The distance to an object is determined by measuring the time of flight of the laser pulses emitted by the LiDaR sensor and reflected by the object. Due to the high precision of object detection and the low dependence on light and weather conditions, LiDaR systems are well suited to supplement existing sensor systems. Some vehicles already have several of these systems installed, and it is expected that this number will continue to rise.

[0005] Car manufacturers want to install ADAS on the vehicle as inconspicuously as possible.

[0006] Typically, sensors for traffic monitoring are located inside the vehicle, usually behind the windshield. Alternatively, it is conceivable to house the sensors in a separate sensor housing, which is then mounted on the outside of the vehicle. However, both internal installation behind the windshield and external installation in a separate sensor housing have significant disadvantages. For example, with LiDaR sensors, due to the inclination of the windshield relative to the road, the laser pulses must traverse the windshield at a very shallow angle, which results in a relatively high deflection, scattering, and absorption of the emitted and reflected photons. Since a significant proportion of the photons are lost for measurement, the performance and efficiency of the LiDaR system are negatively affected.Although this can be avoided by using an externally mounted sensor, this would disrupt the design of the vehicle, as, as described above, it is currently only possible to a limited extent to integrate the sensor housing seamlessly and unobtrusively into the vehicle's external appearance.

[0007] DE 102021 101288 A1 describes a component group with an integrated sensor module lens assembly that can be inserted into a vehicle trim panel. An opening through which the lens assembly extends is provided in a trim panel. The lens assembly can comprise a plurality of lenses. The lenses are aligned so that the optical transmission from a sensor passes through the opening and through the lens assembly. A hard coating can be provided to cover and protect the lens assembly. The component group is separately replaceable and thus still recognizable from the outside when installed in a vehicle trim panel.

[0008] Publication US 2022 / 0281207 A1 describes a cover for a clear substrate, such as a lens in a sensor array, which is applied with a UV-curable pressure-sensitive adhesive. This cover serves to protect against environmental influences.

[0009] The object of the present invention is to avoid the disadvantages of the prior art and to provide a simplified and improved scanner module, preferably a LiDaR scanner module, and to enable the integration of such optoelectric scanners into vehicle components with the best possible or even improved performance and efficiency, as well as without significant disadvantages with regard to the vehicle design. These and other objects are achieved according to the proposal of the invention by a scanner module according to independent patent claim 1. Advantageous embodiments of the invention emerge from the subclaims.

[0010] According to the invention, a scanner module, in particular a LiDaR scanner module for a vehicle attachment is provided, which comprises at least one optoelectrical scanner and an outer cover with a passage area and furthermore the outer cover can be integrated as an outer closing part into the vehicle attachment, in particular seamlessly, or replaces it, wherein at least one optical means with a prism arrangement is arranged between the scanner and the outer cover in the beam path of the optoelectrical scanner, in particular LiDaR scanner.

[0011] The optoelectric scanner is also referred to as “scanner” in the following.

[0012] An optical means is understood to mean a prism arrangement, for example a prism foil or a component with prisms, which is advantageously suitable for increasing the field of view of the scanner, in particular LiDaR scanner, by means of diffraction or refraction.

[0013] The outer cover forms the outer end part of the scanner module. The surface of the end part facing away from the scanner forms the surface facing the environment. This part can be seamlessly fitted, for example, form-fitting or materially bonded, e.g., by adhesive bonding, and fastened or integrated into a vehicle attachment, or it can replace this vehicle attachment. If the outer cover replaces the vehicle attachment, this means that the vehicle attachment is entirely the outer cover, or at least that the vehicle attachment containing the outer cover is manufactured in one piece with it. The penetration area of ​​the outer cover is always the area of ​​the vehicle attachment that is penetrated by the scanner beams, e.g., LiDaR beams (infrared beams).

[0014] The outer aperture, particularly the passage area, is preferably made of a polymer material that is permeable to light in the scanner's operating range and thus provides good transmission for light in the relevant wavelength range. In a LiDaR scanner, the passage area is permeable to wavelengths in the IR range and provides good transmission for IR radiation, particularly in the LiDaR operating range. LiDaR sensors generally operate in a wavelength range of 800–2500 nm, particularly 800–1100 nm, for example, at approximately 905 nm, which belongs to the near-infrared spectrum.

[0015] Various polymer materials, such as polycarbonates, are already known to those skilled in the art. These materials can be used for the outer panel and, if appropriate, for the vehicle attachment containing the outer panel. Materials based on aromatic polycarbonates are particularly suitable and can be selected based on their impact resistance, long-term UV and weather resistance, processability during production, and visual appearance / gloss. Suitable materials for the outer panel are also described, for example, in EP 3395875 A1.

[0016] Polycarbonates typically exhibit high light transmission of more than 80%, especially around 90%, in the relevant wavelength ranges. For example, it is possible to color the polycarbonate so that it transmits virtually no light in the visual spectrum and appears opaque black to the observer, while transmitting no light in the IR range, especially around 905 nm. This allows the outer panel to be visually adapted to the design of the rest of the vehicle's add-on component and concealed.

[0017] In a preferred embodiment, the scanner, in particular a LiDaR scanner and / or the optical means and / or the outer aperture are connected to one another by an optically clear adhesive (OCA). In other words, a materially bonded connection is created between the (LiDaR) scanner and the optical means, or between the optical means and the outer aperture, or both, i.e. between the three elements scanner, optical means and outer aperture. In the latter case, the scanner module can therefore be a firmly and materially bonded unit of the three components. However, it is also possible for only two components of the scanner module to be firmly connected and to be connected and combined with the third for purely functional reasons. For example, a LiDaR scanner can be arranged separately, while the optical means, for example a prism film, is connected directly to the outer aperture.The optically clear adhesive is expediently selected to ensure good transmission of the IR radiation in which the LiDaR scanner operates. The material bond with the optically clear adhesive is advantageously simple and cost-effective to produce. In a further preferred embodiment of the invention, the LiDaR scanner is bonded to the optical element with an optically clear, transparent adhesive (OCA), and the optical element is, in turn, bonded to the outer cover with an optically clear adhesive (OCA). This enables particularly simple production of the scanner module.

[0018] Optically transparent adhesives, for example, are based on silicone. Optically transparent adhesives are particularly known by the acronym LOCA (liquid optically clear adhesive).

[0019] The optically transparent adhesive is curable and can, for example, contain or consist of polyurethane (PU), polyacrylate, polyacetate resin, casting resin, epoxy resin, Acralyt, or a copolymer or mixture thereof. The optically transparent adhesive advantageously consists of a casting resin, particularly polyurethane- or silicone-based. The curable, optically transparent adhesive can be cured by heat, exposure to electromagnetic radiation, preferably UV radiation, and / or chemically. Curing preferably occurs by applying heat or increasing the temperature and / or UV radiation.

[0020] In a further preferred embodiment, the optical means of the scanner module according to the invention is preferably a prism arrangement arranged on the outer diaphragm. This prism arrangement can, for example, be a prism film that is arranged and attached directly to the surface of the outer diaphragm facing the scanner. Alternatively, one or more functional coatings, such as a heating layer, can also be provided between the prism arrangement. Advantageously, the possible field of view magnification is maximized by arranging the optical means as close as possible to the outer diaphragm and thus to the exit field of the IR radiation. Thus, with the scanner module according to the invention, the detection range can be significantly enlarged and its efficiency increased.A further advantage is that the outer panel with the optical means, for example, with applied prism film, optionally with additional functional coatings, can be manufactured as a prefabricated intermediate product. In another preferred embodiment, the prism arrangement is formed in the surface of the outer panel facing the scanner. In other words, the prism arrangement is manufactured integrally with the outer panel. In one embodiment, the vehicle attachment therefore contains the outer panel and the prism arrangement as a uniform, possibly one-piece component. The outer panel with the prism arrangement can, for example, be manufactured as an injection-molded part.

[0021] In a preferred embodiment, a coating to increase scratch resistance and / or an anti-reflection coating is additionally applied to the outer panel, for example on a surface facing the environment.

[0022] Suitable materials for the scratch-resistant coating or the anti-reflective coating are known to those skilled in the art. For example, polysiloxane lacquers produced by the sol-gel process can be used as scratch-resistant coatings. Various methods are known for producing a scratch-resistant coating on plastic articles. These systems can be applied, for example, using dipping processes, spin coating, spraying processes, or flow coating, preferably using dipping or flow processes. Curing can occur thermally or by means of UV irradiation. The scratch-resistant coating can be applied, for example, directly or after preparing the substrate surface with a primer. Furthermore, a scratch-resistant coating can be applied using plasma-assisted polymerization processes, e.g., using an SiO2 plasma. Anti-fog or anti-reflective coatings can also be produced using plasma processes.Furthermore, it is possible to apply a scratch-resistant coating to the resulting molded article using certain injection molding processes, such as back-injection molding of surface-treated films. Various additives, such as UV absorbers derived from triazoles or triazines, can be present in the scratch-resistant coating. Preferred UV absorbers include HALS compounds.

[0023] In another preferred embodiment of the scanner module according to the invention, a bandpass filter is additionally provided on or in the outer panel.

[0024] A preferably used bandpass filter blocks irrelevant wavelength ranges for the respective desired and configured operation of the scanner, for example those above and below approximately 905 nm in a LiDaR scanner, so that the impairment of the sensor by these other wavelengths is avoided and a higher operational precision is enabled.

[0025] Bandpass filters are used in many applications and can be designed either as dichroic filters or as colored glass filters. Dichroic or coated bandpass filters are divided into two types: conventionally vapor-deposited filters and sputtered, or hard-coated, filters. In both processes, the specific transmission and reflection properties are achieved by depositing several layers of material with alternating high and low refractive indices on glass substrates. Depending on the application, 100 or more layers can be deposited on a single substrate surface.

[0026] The difference between conventionally coated bandpass filters and hard-coated bandpass filters lies in the number of substrate layers. With conventionally coated bandpass filters, multiple substrates are coated and then arranged one behind the other. This process results in a thick filter with limited transmission. This reduced transmission is caused by the incident light being absorbed or reflected by multiple substrate layers. With hard-coated bandpass filters, however, almost any number of layers can be applied to a single substrate. It is not necessary to use multiple layers. This process then results in thinner filters with high transmission in the desired wavelength range.

[0027] In another preferred embodiment, the optical means and / or the outer cover of the scanner module according to the invention additionally have a coating and / or a film with a heating and / or defrosting function. This ensures that the scanner functions are not significantly adversely affected by icing or fogging, even in winter.

[0028] For example, the outer panel can preferably additionally comprise a film or coating with a defrosting function. Such films with a defrosting function are described, for example, in European patent EP 1438172 B1. This is generally a thin polycarbonate film carrying heating wires. The film with the defrosting function can be integrated into or applied to the outer panel using film insert molding (FIM).

[0029] In a preferred embodiment of the scanner module, the vehicle attachment is the A-, B-, and / or C-pillar, preferably their trims, front trims, radiator grille, preferably radiator grille, spoiler, and / or rear trim. Particularly preferably, the vehicle attachment is the B-pillar of a vehicle. The scanner module is preferably a LiDaR scanner module.

[0030] The present invention further comprises a vehicle having a LiDaR scanner module, in particular a LiDaR scanner module as described above in various embodiments and combinations, wherein the outer panel forms an integrated part of an attachment part of the vehicle or a complete attachment part of the vehicle.

[0031] The scanner module is conveniently connected to a voltage source and a control and / or evaluation unit, for example to the on-board electronics and on-board computer of a vehicle.

[0032] Furthermore, the invention also relates to a method for producing a scanner module, in particular a LiDaR scanner module, as described above in various embodiments, comprising the steps

[0033] (a) Providing an outer panel, preferably with a passage area,

[0034] (b) Providing a scanner, preferably a LiDaR scanner,

[0035] (a) Connecting the scanner and / or the outer aperture to an optical means using an optically clear adhesive. The optical means is arranged between the scanner and the outer aperture in the beam path of the scanner. Preferably, the outer aperture and / or the scanner are connected to the optical means, preferably by a material bond using the optically clear adhesive. Preferably, the outer aperture and / or the scanner are connected to the optical means, preferably by a material bond using an optically clear adhesive. The outer aperture, or at least the passage area of ​​the outer aperture, is expediently made of a polymer material that is permeable to light with wavelengths in the operating range of the optoelectric scanner. In LiDaR scanners, this is in the IR range. LiDaR sensors generally operate in a wavelength range of 800–1500 nm, for example, at approximately 905 nm, which belongs to the near-infrared spectrum.

[0036] Prism arrangements, for example as microprism films or layers, are used as an optical means which advantageously enables an enlargement of the field of view of the scanner module, in particular the LiDaR scanner module, for example by diffraction or refraction.

[0037] In one variant of the process, the optical device is bonded to the scanner using an optically clear adhesive (OCA). Preferably, a bonded connection to the outer panel is also created using OCA. Alternatively, a bonded connection to the outer panel can be created first, followed by the connection of the optical device to the LiDAR scanner. The LiDAR scanner module can then be precisely inserted and integrated into a vehicle component, for example, as a connected functional unit.

[0038] The connection between the exterior panel and the vehicle attachment can also be achieved, for example, in a so-called flush injection molding, even as a seamless integration into or behind existing vehicle attachments. Such vehicle attachments include, for example, front panels, spoilers, radiator grilles, radiator grilles, A-, B-, and C-pillar trims, exterior mirror covers, roof trims, rear trims, and bumpers. According to the invention, the integration of the scanner module according to the invention, preferably a LiDaR scanner module, into side attachments of a vehicle, such as the B-pillar or B-pillar trim, is preferred.

[0039] Using two-component injection molding, it is possible, for example, to mold two types of polycarbonate together to create a single vehicle component with an integrated outer cover. This component meets the necessary transmission properties for the scanner radiation, for example, LiDaR IR radiation, for the outer cover, and the vehicle component has a passage area that is transparent to (IR) radiation. At the same time, the invention enables the integration of the scanner module into various designs and in various positions, which significantly increases design freedom for automobile manufacturers. This also leads to a reduction in manufacturing costs.

[0040] In a preferred embodiment of the method, the optical means, for example a prism film, is arranged directly on the surface of the outer aperture facing the scanner and secured, for example, by adhesive bonding. By maximizing the distance to the scanner, the possible field of view magnification provided by the prisms is also optimized.

[0041] In another embodiment of the method, the optical means is formed as a prism arrangement directly in a surface of the outer diaphragm facing the scanner, preferably integrally with the outer diaphragm by an injection molding process. This further simplifies the method.

[0042] In one embodiment of the method, the optical means and / or the outer cover are additionally provided with a coating and / or a film with a heating and / or defrosting function. This ensures that the sensor functions of the scanner are not significantly negatively affected by icing or fogging, even in winter.

[0043] In a further embodiment of the method, it is provided that the outer panel is provided with an additional functional layer, preferably a coating to increase scratch resistance and / or an anti-reflection coating.

[0044] Within the scope of the present invention, preferred embodiments mentioned for individual features can also be freely combined with one another, provided they are not contradictory or are explicitly mentioned only as alternatives. This also applies to features mentioned only for the scanner module, for example, the LiDaR scanner module, or only for the method.

[0045] The invention will be explained in more detail below using exemplary embodiments, with reference to the accompanying figures. They show, in a simplified, not-to-scale representation: Fig. 1 is a schematic cross-sectional view of a first embodiment of a scanner module according to the invention,

[0046] Fig. 2 is a schematic cross-sectional view of a further embodiment of a scanner module according to the invention,

[0047] Fig. 3 is a schematic representation of an embodiment of a vehicle attachment containing a scanner module according to the present invention in a perspective view, and

[0048] Fig. 4 is a schematic representation of another embodiment of a vehicle attachment containing a scanner module according to the present invention in a perspective view.

[0049] Figure 1 shows a schematic cross-sectional view of an embodiment of a scanner module 1 according to the invention, in which an optical means 5, in the illustration a prism arrangement 5, is arranged directly on the outer aperture 4 in the beam path of the scanner. This arrangement of the optical means 5 at the passage area D of the outer aperture 4 results in a significantly enlarged field of view for the scanner 3. The prism arrangement 5 can, for example, be designed as a prism film, which is connected, for example, by adhesive bonding, to the surface of the outer aperture 4 facing the scanner 3. The scanner 3 can be connected purely functionally to the optical means 5 and, if applicable, the outer aperture 4, or via a material-to-material connection using an optically clear adhesive. The production of such a scanner module 1 according to the invention is also simple and cost-effective.The optical means 5 and / or the outer cover 4 can further be provided with functional coatings, which are not shown in the figure, however. Such coatings include, for example, heating layers, anti-reflective layers, or scratch-resistant coatings. The scanner 3, or the scanner module 1, is of course connected in the usual manner to a voltage source and a control and / or evaluation unit, for example, to the on-board electronics and on-board computer of a vehicle, or contains these.

[0050] Figure 2 shows a schematic cross-sectional view of another embodiment of a scanner module 1 according to the invention, wherein, in contrast to the embodiment in Figure 1, the optical means 5 is arranged and formed as a prism arrangement 5 integrally with the outer aperture 4 in the surface directed towards the scanner 3 and thus in the beam path of the scanner. This maximizes the distance to the scanner and results in a significantly enlarged field of view for the scanner 3 at the passage area D of the outer aperture 4. The outer aperture 4 with the prism arrangement 5 can be manufactured, for example, by an injection molding process.

[0051] Figure 3 schematically shows, in a perspective top view, an exemplary embodiment of a vehicle attachment 2, namely an exterior mirror 2A, containing a scanner module 1 according to the invention, for example a LiDaR scanner module. The outer cover 4 has a (LiDaR) passage area D, which is preferably visually indistinguishable from the surrounding material of the outer cover 4.

[0052] Figure 4 shows a perspective top view, schematically, of another exemplary embodiment of a vehicle attachment 2 containing a scanner module 1 according to the invention. In this illustration, the vehicle attachment 2B is a B-pillar for a vehicle. The outer panel is therefore elongated. The outer panel has a passage area D, which is preferably visually indistinguishable from the outside from the surrounding material of the outer panel of the B-pillar 2B. The outer panel thus advantageously also conceals the other components of the scanner module from the outside. The rays penetrating outwards through the passage area, for example IR rays from a LiDaR sensor, are only occasionally indicated schematically as dashed lines.

[0053] The improved scanner module 1 according to the invention enables the integration of scanners into vehicle components 2 with the best possible or even improved performance and efficiency. This is advantageously achieved in addition to increased design freedom. Furthermore, manufacturing is simple and cost-effective and can also be transferred to industrial series production.

[0054] 1 scanner module

[0055] 2 Vehicle attachment 2A Vehicle attachment / Exterior mirror

[0056] 2B Vehicle attachment / B-pillar

[0057] 3 scanners

[0058] 4 Outer panel

[0059] 5 optical means (prisms / prism arrangement)

[0060] 6 optically clear adhesive (OCA)

[0061] 6a, 6b optically clear adhesive (attachment areas with OCA)

[0062] D Passage area

Claims

Patent claims 1. Scanner module (1), in particular LiDaR scanner module, for a vehicle attachment (2) at least comprising a scanner (3), preferably a LiDaR scanner, and an outer panel (4) with a passage area (D), wherein furthermore the outer panel (4) can be integrated into the vehicle attachment (2) as an outer closing part or replaces it, characterized in that at least one optical means (5) with a prism arrangement (5b) is arranged in the beam path of the scanner between the scanner (3) and the outer panel (4).

2. Scanner module (1) according to claim 1, characterized in that the scanner (3), and / or the optical means (5) and / or the outer panel (4) are connected to one another by an optically clear adhesive (OCA) (6).

3. Scanner module (1) according to claim 1 or 2, characterized in that the scanner (3) is connected to the optical means (5) with an optically clear adhesive (6) and the optical means (5) is in turn connected to the outer panel (4) with an optically clear adhesive (6).

4. Scanner module (1) according to one of claims 1 to 3, characterized in that the optical means (5), preferably a prism film (5b), is arranged on the outer diaphragm (4).

5. Scanner module (1) according to one of claims 1 to 4, characterized in that the prism arrangement is formed in the surface of the outer aperture (4) directed towards the scanner.

6. Scanner module (1) according to one of claims 1 to 5, characterized in that the outer panel (4) additionally has a coating for increasing scratch resistance and / or an anti-reflection coating on a surface facing the environment.

7. Scanner module (1) according to one of claims 1 to 6, characterized in that a bandpass filter is additionally provided on or in the outer panel (4).

8. Scanner module (1) according to one of claims 1 to 7, characterized in that the optical means (5) and / or the outer cover (4) additionally has a coating and / or a film with a heating and / or defrosting function.

9. Scanner module (1) according to one of claims 1 to 8, characterized in that the vehicle attachment part (2) is the A-, B- and / or C-pillar (2), preferably its panels, front panels, radiator grille, preferably radiator panel, spoiler and / or rear panel.

10. Vehicle comprising a scanner module (1), in particular a LiDaR scanner module according to one of claims 1 to 9, characterized in that the outer panel (4) forms an integrated part of an attachment part of the vehicle (2) or a complete vehicle attachment part (2).

11. A method for producing a scanner module (1) according to one of claims 1 to 10, characterized in that it comprises the following steps: (a) Providing an outer panel (4) (b) Providing a scanner (3), preferably a LiDaR scanner, (c) connecting the outer aperture (4) and / or the scanner (3) to an optical means (5) using an optically clear adhesive (6), wherein the optical means (5) is arranged between the scanner (3) and the outer aperture (4) in the beam path of the scanner (3).

12. Method according to claim 11, characterized in that the optical means (5) is applied to a surface of the outer panel (4) facing the scanner (3).

13. Method according to claim 11 or 12, characterized in that the optical means (5) is formed as a prism arrangement in a surface of the outer diaphragm (4) facing the scanner (3), preferably in one piece therewith by an injection molding process.

14. Method according to one of claims 11 to 13, characterized in that the optical means (5) and / or the outer diaphragm (4) is additionally provided with a coating and / or with a film with a heating and / or defrosting function.

15. Method according to one of claims 11 to 14, characterized in that the outer panel is provided with an additional functional layer, preferably a coating to increase scratch resistance and / or an anti-reflection coating.

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