Radar sensor enclosure shaped as a lens

Abstract

A sensor system, having: an enclosure extending longitudinally between first and second ends and laterally between first and second sides; the enclosure including: first and second sidewalls extending depthwise to define the first and second sides, from first and second aft ends to first and second front ends; a front wall extending between the first and second front ends, the front wall having an arcuate shape and defining a lens with a single-focal point; and first and second antennas disposed in the enclosure, side by side, near the front wall.

Description

133456WO01 (WKP0189PCT)RADAR SENSOR ENCLOSURE SHAPED AS A LENSCROSS REFERENCE

[0001] This application claims priority to US63 / 738153, filed on December 23, 2024, the entire contents of which is incorporated herein by reference.BACKGROUND

[0002] The disclosure relates to radar and more specifically to a radar sensor enclosure shaped as a lens.

[0003] There is a need to improve an effectiveness of emission of radar signal in a field of view (FoV). A microwave lens may improve an effectiveness of a radar signal emission in a defined FoV, however various issues exist. Lenses are additional elements to a system, which increases a bill of material (BOM) cost, complexity of a mechanical design of the system, and costs related to an assembly of the system. Separate neighboring antennas for transmitting and receiving radar signals may be utilized, though may require a lens with two independent focal points to achieve desired performance.BRIEF SUMMARY

[0004] Disclosed is a sensor system, including: an enclosure extending longitudinally between first and second ends and laterally between first and second sides; the enclosure including: first and second sidewalls extending depthwise to define the first and second sides, from first and second aft ends to first and second front ends; a front wall extending between the first and second front ends, the front wall having an arcuate shape and defining a lens with a single-focal point; and first and second antennas disposed in the enclosure, side by side, near the front wall.

[0005] In addition to one or more aspects of the system, or as an alternate, the first antenna is configured as transmitter antenna and the second antenna is configured as receiver antenna.133456WO01 (WKP0189PCT)

[0006] In addition to one or more aspects of the system, or as an alternate, the enclosure defines an enclosure lateral center and is symmetric about the enclosure lateral center.

[0007] In addition to one or more aspects of the system, or as an alternate, the first and second antennas are symmetrically positioned about the enclosure lateral center.

[0008] In addition to one or more aspects of the system, or as an alternate, the front wall defines an outer surface and inner surface, wherein the outer surface defines a portion of an ellipse having a major axis that extends between the first and second front ends of the first and second sidewalls and a minor axis that is located on the enclosure lateral center.

[0009] In addition to one or more aspects of the system, or as an alternate, the front wall defines a first portion extending away from the first sidewall toward the enclosure lateral center, a second portion extending away from the second sidewall toward the enclosure lateral center, and a third portion at the enclosure lateral center, wherein the first portion has a first thickness, the second portion has a second thickness and the first and second thicknesses are the same as each other.

[0010] In addition to one or more aspects of the system, or as an alternate, the front wall defines a continuous arcuate curvature between the first and second front ends of the first and second sidewalls.

[0011] In addition to one or more aspects of the system, or as an alternate, the continuous curvature is a portion of a circle or ellipse.

[0012] In addition to one or more aspects of the system, or as an alternate, the third portion has a bulbus shape, having a maximum thickness that is greater than the first and second thicknesses.

[0013] In addition to one or more aspects of the system, or as an alternate, the third portion defines a longitudinally extending polygonal channel.133456WO01 (WKP0189PCT)

[0014] Disclosed is a method of manufacturing a sensor system, including: defining an enclosure extending longitudinally between first and second ends and laterally between first and second sides; the enclosure including: first and second sidewalls extending depth wise to define the first and second sides, from first and second aft ends to first and second front ends; a front wall extending between the first and second front ends, the front wall having an arcuate shape and defining a lens with a single-focal point; manufacturing the enclosure; and positioning first and second antennas in the enclosure, side by side, near the front wall.

[0015] In addition to one or more aspects of the method, or as an alternate, the method includes configuring the first antenna as transmitter antenna and the second antenna as receiver antenna.

[0016] In addition to one or more aspects of the method, or as an alternate, the method includes defining the enclosure to have an enclosure lateral center and such that the enclosure is symmetric about the enclosure lateral center.

[0017] In addition to one or more aspects of the method, or as an alternate, the method includes positioning the first and second antennas symmetrically about the enclosure lateral center.

[0018] In addition to one or more aspects of the method, or as an alternate, the method includes defining the front wall to have an outer surface and inner surface, such that the outer surface defines a portion of an ellipse having a major axis that extends between the first and second front ends of the first and second sidewalls and a minor axis that is located on the enclosure lateral center.

[0019] In addition to one or more aspects of the method, or as an alternate, the method includes defining the front wall to have a first portion extending away from the first sidewall toward the enclosure lateral center, a second portion extending away from the second sidewall toward the enclosure lateral center, and a third portion at the enclosure lateral center, wherein the first portion has a first thickness, the second portion has a second thickness and the first and second thicknesses are the same as each other.133456WO01 (WKP0189PCT)

[0020] In addition to one or more aspects of the method, or as an alternate, the method includes defining the front wall to have a continuous arcuate curvature between the first front end and the second front end of the first and second sidewalls.

[0021] In addition to one or more aspects of the method, or as an alternate, the method includes defining the continuous curvature to be a portion of a circle or ellipse.

[0022] In addition to one or more aspects of the method, or as an alternate, the method includes defining the third portion to have a bulbus shape, having a maximum thickness that is greater than the first and second thicknesses.

[0023] In addition to one or more aspects of the method, or as an alternate, the method includes defining the third portion to have a longitudinally extending polygonal channel.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present disclosure is illustrated by way of example and not limited to the accompanying figures in which like reference numerals indicate similar elements.

[0025] FIG. 1 is a perspective view of a system having a radar sensor enclosure shaped as a lens, according to an embodiment;

[0026] FIG. 2 is a top view of the system, according to an embodiment;

[0027] FIG. 3 is a top view of a front wall of the enclosure, according to another embodiment;

[0028] FIG. 4 is a top view of a front wall of the enclosure, according to a further embodiment; and

[0029] FIG. 5 is a method of manufacturing a system having a radar sensor enclosure shaped as a lens, according to an embodiment.DETAILED DESCRIPTION133456WO01 (WKP0189PCT)

[0030] Turning to FIGS. 1 and 2, the figures show a radar sensor system (for simplicity, a system) 100 having an enclosure 120 shaped as a lens. The enclosure 120 extends longitudinally between first and second ends 130 A, 130B, and laterally between first and second sides 140A, 140B.

[0031] The enclosure 120 includes first and second sidewalls 150A, 150B extending depthwise D to define the first and second sides 140 A, I40B of the enclosure 120. The first and second sidewalls 150A, 150B extend from first and second aft ends 160A, 160B to first and second front ends 170A, 170B. A front wall 180 extends between the first and second front ends 170A, 170B. The front wall 180 has an arcuate shape SI and defines a lens with a single-focal point Pl.

[0032] First and second antennas 190A, 190B are disposed in the enclosure 120. The first and second antennas 190A, 190B are side by side, near the front wall 180. The first and second antennas 190A, 190B may be installed on a printed circuit board 200 within the enclosure 120.

[0033] According to an embodiment, the first antenna 190A is configured as transmitter antenna. The second antenna 190B is configured as receiver antenna. According to an embodiment, the enclosure 120 defines an enclosure lateral center 210. The enclosure 120 may be symmetric about the enclosure lateral center 210. According to an embodiment, the first and second antennas 190A, 190B are symmetrically positioned about the enclosure lateral center 210.

[0034] According to an embodiment, the front wall 180 defines an outer surface 220A and an inner surface 220B. The outer surface 220A defines a portion of an ellipse having a major axis Al that extends between the first and second front ends 170A, 170B of the first and second sidewalls 150A, 150B. A minor axis A2 is located on the enclosure lateral center 210.

[0035] Turning to FIG. 3, aspects of the front wall 180 are shown according to an embodiment. The other aspects of the enclosure 120 and system 100 are the same as shown in FIGS. 1 and 2.133456WO01 (WKP0189PCT)

[0036] The front wall 180 defines a first portion 230A extending away from the first sidewall 150A toward the enclosure lateral center 210. A second portion 230B of the front wall 180 extends away from the second sidewall 150B toward the enclosure lateral center 210. . A third portion 230C of the front wall 180 is located at the enclosure lateral center 210. The antenna 190A, 190B are shown for reference.

[0037] The first portion 230A of the front wall 180 has a first thickness Tl. The second portion 230B of the front wall 180 has a second thickness T2. In one embodiment, the first and second thicknesses Tl, T2 are the same as each other. According to an embodiment, the arcuate shape SI of the front wall 180 defines a continuous arcuate curvature. The continuous curvature may be a portion of a circle or ellipse in cross section. The continuous curvature Cl extends between the first and second front ends 170A, 170B of the first and second sidewalls 150A, 150B (FIG. 2).

[0038] According to the embodiment of FIG. 3, the third portion 230C of the front wall 180 has a bulbus shape, the enclosure lateral center 210, having a maximum thickness T3 that is greater than the first and second thicknesses Tl, T2 of the first and second portions 230A, 230B of the front wall 180.

[0039] A first radiation pattern 300A from the first antenna 190A and a second radiation pattern 300B from the second antenna 190B are shown. With the disclosed embodiment, the radiation patterns for the transmitting antenna 190A and receiving antenna 190B will be asymmetrical. However the patterns will be mirror images with respect to a plane perpendicular to the plane PL1 extending depthwise through the enclosure lateral center 210, with the radiation maximum angularly distant from the perpendicular plane. As a result of the configuration of the system 100, the sum of the radiation patterns from the antenna 190A, 190B is symmetrical. Radar range depends on summed directivity from transmitting and receiving antennas 190A, 190B, which is improved in with the disclosed embodiments as compared with known solutions.133456WO01 (WKP0189PCT)

[0040] Turning to FIG. 4, the figure shows an embodiment of the front wall 180 of the enclosure 120 that is the same as the embodiment of FIG. 3 except as indicated. The other aspects of the enclosure 120 and system 100 are the same as shown in FIGS. 1 and 2. According to the embodiment of FIG. 5, the third portion 230C of the front wall 180 defines a longitudinally extending polygonal channel 240, centered on the enclosure lateral center 210, that extends inwardly, toward the antenna 190A, 190B.

[0041] A first radiation pattern 300A from the first antenna 190A and a second radiation pattern 300B from the second antenna 190B are shown. With the disclosed embodiment, the radiation patterns for the transmitting antenna 190A and receiving antenna 190B will be asymmetrical. However the patterns will be mirror images with respect to a plane perpendicular to the plane PL1 extending depthwise through the enclosure lateral center 210, with the radiation maximum angularly distant from the perpendicular plane. As a result of the configuration of the system 100, the sum of the radiation patterns from the antenna 190A, 190B is symmetrical. Radar range depends on summed directivity from transmitting and receiving antennas 190A, 190B, which is improved in with the disclosed embodiments as compared with known solutions.

[0042] Turning to FIG. 5, a flowchart shows a method of manufacturing a sensor system 100. As shown in block 1010, the method includes defining an enclosure 120 extending longitudinally between first and second ends 130A, 130B and laterally between first and second sides 140 A, HOB. The enclosure includes first and second sidewalls 150A, 150B extending depthwise to define the first and second sides 140A, HOB, from first and second aft ends 160A, 160B to first and second front ends 170A, 170B. The enclosure 120 further includes a front wall 180 extending between the first and second front ends 170A, 170B. The front wall 180 has an arcuate shape SI and defining a lens with a single-focal point Pl.

[0043] As shown in block 1020, the method includes manufacturing the enclosure 120. For example, the enclosure is additively manufactured. As shown in block 1030, the method includes positioning first and second antennas 190A, 1906133456WO01 (WKP0189PCT)in the enclosure 120, side by side, near the front wall 180. As shown in block 1040, the method includes configuring the first antenna 190A as transmitter antenna and the second antenna 190B as receiver antenna.

[0044] As shown in block 1050, the method includes defining the enclosure 120 to have an enclosure lateral center 210 such that the enclosure 120 is symmetric about the enclosure lateral center 210. As shown in block 1060, the method includes positioning the first and second antennas 190 A, 190B symmetrically about the enclosure lateral center 210.

[0045] As shown in block 1070, the method includes defining the front wall 180 to have an outer surface 220A and inner surface 220B. The outer surface 220A defines a portion of an ellipse having a major axis Al that extends between the first and second front ends 170A, 170B of the first and second sidewalls 150A, 150B. A minor axis A2 is located on the enclosure lateral center 210.

[0046] As shown in block 1080, the method includes defining the front wall 180 to have a first portion 230A extending away from the first sidewall 150A toward the enclosure lateral center 210. A second portion 230B extends away from the second sidewall 150B toward the enclosure lateral center 210. A third portion 230C is located at the enclosure lateral center 210. The first portion 230A has a first thickness Tl. The second portion 230B has a second thickness T2 and the first and second thicknesses Tl, T2 are the same as each other.

[0047] As shown in block 1090, the method includes defining the front wall 180 such that arcuate shape S 1 is a continuous arcuate curvature between the first front end 170A and the second front end 170B of the first and second sidewalls 150A, 150B. As shown in block 1100, the method includes defining the continuous curvature to be a portion of a circle or ellipse.

[0048] As shown in block 1110, the method includes defining the third portion 230C to have a bulbus shape, having a maximum thickness T4 that is greater than the first and second thicknesses Tl, T2. As shown in block 1120, the method133456WO01 (WKP0189PCT)includes defining the third portion 230C to have a longitudinally extending polygonal channel 240.

[0049] The above embodiments provide an enclosure 120 that is utilized as a lens. The enclosure 120 is shaped as a single-focus lens for two antennas 190 A, 190B placed side by side, equidistant from the lens focal point Pl defined by the enclosure 120.

[0050] With the disclosed embodiment, the radiation patterns for the transmitting antenna 190A and receiving antenna 190B will be asymmetrical. However, the patterns will be mirror images with respect to a plane perpendicular to the plane PL1 extending depthwise through the enclosure lateral center 210, with the radiation maximum angularly distant from the perpendicular plane. As a result of the configuration of the system 100, the sum of the radiation patterns from the antenna 190 A, 190B is symmetrical. Radar range depends on summed directivity from transmitting and receiving antennas 190 A, 190B, which is improved in with the disclosed embodiments as compared with known solutions.

[0051] For example, using the disclosed shaped enclosure 120 as lens, instead of a flat lens, there may be an improvement in the cumulative directivity of the transmission and receiving antennas in an angle range from -45 to 45 degrees, from 0.3 to l.ldB. This results in a radar range that is improved by about 3-10%. As another example, using the shaped enclosure 120 as a lens instead of no enclosure, there may be an improvement to the cumulative directivity of transmission and receiving antennas in an angle range from -45 to 45 degrees, from 0.3 to 0.5dB. This results in a radar range that is improved by about 3-5%.

[0052] As can be appreciated, the embodiments provide a dual functionality of an enclosure 120, protection of enclosed antenna, and functioning as an RF (radio frequency) lens. Shaping the enclosure 120 to define a single focal point lens improves radar performance and achieves a symmetric effective summed transmission and receiving radiation patterns, relative to an orthogonal plane. Thus, the embodiments provide an improved performance without increasing133456WO01 (WKP0189PCT)manufacturing or assembly costs, and provide a more effective of radar detection in a defined FoV.

[0053] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. The term “about” is intended to include the degree of error associated with measurement of the particular quantity and / or manufacturing tolerances based upon the equipment available at the time of filing the application. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and / or groups thereof.

Claims

133456WO01 (WKP0189PCT)What is claimed is:

1. A sensor system, comprising:an enclosure extending longitudinally between first and second ends and laterally between first and second sides;the enclosure including:first and second sidewalls extending depthwise to define the first and second sides, from first and second aft ends to first and second front ends;a front wall extending between the first and second front ends, the front wall having an arcuate shape and defining a lens with a single-focal point; and first and second antennas disposed in the enclosure, side by side, near the front wall.

2. The system of claim 1, wherein the first antenna is configured as transmitter antenna and the second antenna is configured as receiver antenna.

3. The system of claim 1 or 2, wherein the enclosure defines an enclosure lateral center and is symmetric about the enclosure lateral center.

4. The system of any of claims 1-3, wherein the first and second antennas are symmetrically positioned about the enclosure lateral center.

5. The system of any of claims 1-4, wherein the front wall defines an outer surface and inner surface, wherein the outer surface defines a portion of an ellipse having a major axis that extends between the first and second front ends of the first and second sidewalls and a minor axis that is located on the enclosure lateral center.133456WO01 (WKP0189PCT)6. The system of any of claims 1-5, wherein the front wall defines a first portion extending away from the first sidewall toward the enclosure lateral center, a second portion extending away from the second sidewall toward the enclosure lateral center, and a third portion at the enclosure lateral center, wherein the first portion has a first thickness, the second portion has a second thickness and the first and second thicknesses are the same as each other.

7. The system of any of claims 1-6, wherein the front wall defines a continuous arcuate curvature between the first and second front ends of the first and second sidewalls.

8. The system of any of claims 1-7, wherein the continuous curvature is a portion of a circle or ellipse.

9. The system of any of claims 1-8, wherein the third portion has a bulbus shape, having a maximum thickness that is greater than the first and second thicknesses.

10. The system of any of claims 1-9, wherein the third portion defines a longitudinally extending polygonal channel.

11. A method of manufacturing a sensor system, comprising: defining an enclosure extending longitudinally between first and second ends and laterally between first and second sides;the enclosure including:first and second sidewalls extending depthwise to define the first and second sides, from first and second aft ends to first and second front ends;a front wall extending between the first and second front ends, the front wall having an arcuate shape and defining a lens with a single-focal point;manufacturing the enclosure; and133456WO01 (WKP0189PCT)positioning first and second antennas in the enclosure, side by side, near the front wall.

12. The method of claim 11 , comprising configuring the first antenna as transmitter antenna and the second antenna as receiver antenna.

13. The method of claim 11 or 12, comprising defining the enclosure to have an enclosure lateral center and such that the enclosure is symmetric about the enclosure lateral center.

14. The method of any of claims 11-13, comprising positioning the first and second antennas symmetrically about the enclosure lateral center.

15. The method of any of claims 11-14, comprising defining the front wall to have an outer surface and inner surface, such that the outer surface defines a portion of an ellipse having a major axis that extends between the first and second front ends of the first and second sidewalls and a minor axis that is located on the enclosure lateral center.

16. The method of any of claims 11-15, comprising defining the front wall to have a first portion extending away from the first sidewall toward the enclosure lateral center, a second portion extending away from the second sidewall toward the enclosure lateral center, and a third portion at the enclosure lateral center, wherein the first portion has a first thickness, the second portion has a second thickness and the first and second thicknesses are the same as each other.

17. The method of any of claims 11-16, comprising defining the front wall to have a continuous arcuate curvature between the first front end and the second front end of the first and second sidewalls.

18. The method of any of claims 11-17, comprising defining the continuous curvature to be a portion of a circle or ellipse.133456WO01 (WKP0189PCT)19. The method of any of claims 11-18, comprising defining the third portion to have a bulbus shape, having a maximum thickness that is greater than the first and second thicknesses.

20. The method of any of claims 11-19, comprising defining the third portion to have a longitudinally extending polygonal channel.

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