Integrated Camera Cover Geometry to Reduce Vehicle Fogging

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Solution Overview

Problem

Existing vehicle add-on parts with integrated camera modules face challenges in minimizing fogging from water vapor, maintaining invisibility, and reducing production costs, as they often require complex sensor technology and additional components like microporous membranes or anti-fogging layers.

Innovation Solution

A vehicle add-on part with a camera module integrated into a cover made partially of transparent thermoplastic material, featuring local thickening and thinning to minimize the cavity between the camera lens and the cover, eliminating the need for microporous membranes and enhancing optical properties by acting as a light guide.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If microporous membranes are integrated into the add-on part to prevent water vapor condensation, then fogging risk is reduced, but production costs increase and manufacturing complexity increases

Engineering Contradiction:

Improvefogging preventionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the microporous membrane component entirely from the system. Instead of using a membrane to prevent condensation, the design accepts that some condensation may occur but mitigates it through geometric design (cambered cover) and material selection (hydrophobic coating), thereby eliminating the complex manufacturing step of integrating microporous membranes while maintaining acceptable fogging prevention

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the physical parameters of the cover by introducing a cambered (curved) design instead of a flat surface. This geometric parameter change creates natural drainage paths for condensation and facilitates evaporation, replacing the need for microporous membranes while maintaining fogging prevention functionality

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the camera module is mounted with larger installation space to accommodate non-perpendicular viewing direction, then the camera can image road parts, but water or water vapor entry risk increases

Engineering Contradiction:

Improveviewing angleVSAvoidwater entry risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a cambered (curved) dimension to the cover design, transforming it from a flat two-dimensional surface to a three-dimensional curved surface. This dimensional change creates slope and drainage paths that prevent water accumulation and facilitate vapor evaporation, allowing the camera to be positioned for non-perpendicular viewing while maintaining protection against water entry

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If anti-fogging layers are applied to the pane surface, then fogging is prevented, but production costs increase

Engineering Contradiction:

Improvefogging preventionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the surface energy parameters of the cover material by selecting or treating the material to be hydrophobic. This parameter change in surface properties prevents water and condensation from adhering to the surface, providing anti-fogging functionality without the need for additional anti-fogging layers or coatings, thereby reducing production costs

Inventive Principle:

Principle #35Parameter changes

4Illumination intensity

If the cover is made of mineral glass to maintain optical properties, then optical performance is good, but weight increases

Engineering Contradiction:

Improveoptical propertiesVSAvoidcover weight

Core Design Contradiction:

Illumination intensityVSWeight of stationary object

Solution Approach 1:

The patent changes the material parameter from mineral glass to transparent thermoplastic material. This material substitution maintains adequate optical transparency and light-gathering properties while significantly reducing the weight of the cover, achieving a favorable weight-to-optical-performance ratio

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces the risk of fogging, minimizes the camera module's visibility, and simplifies production by eliminating additional components, while providing improved optical properties and weight reduction compared to mineral glass.

Implementation Method 1

improving optical properties by acting as a light guide

Methodology Applied

Scientific EffectLight guide: Waveguide (optics)

Implementation Method 2

minimize the cavity between the camera lens and the cover, eliminating the need for microporous membranes and enhancing optical properties

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS11780379B2Add-on part having an integrated camera module

Publication Date: 2023.10.10 FREEGLASS

AI summary

A vehicle add-on part for integrating a camera module includes a cover, which consists at least partially of a transparent thermoplastic material, a carrier part for a camera module, and a camera module having at least one camera lens. The transparent thermoplastic material of the cover has, on the inner side, a local thickening and/or a local thinning, and the camera module is held in the carrier part such that the at least one camera lens of the camera module is arranged directly opposite the thickening and/or the thinning.