Conductive Polymer Sensor Housing for Integral Defrosting
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Solution Overview
Problem
Current sensor systems in vehicles, especially those outside the cabin, face issues with ice, snow, and condensation buildup, requiring manual clearing which can be damaging and inconvenient, as they rely on internal defroster systems that may not effectively reach external sensors.
Innovation Solution
A sensor assembly with a housing made of electrically conductive polymeric material that heats up when an electrical current is applied, melting snow and ice or removing frost and condensation without additional heating circuits, allowing for external mounting and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are mounted outside the vehicle cabin, then the sensors can be positioned for optimal detection, but they become vulnerable to ice, snow, and condensation buildup requiring manual clearing
Solution Approach 1:
The housing material itself serves the dual function of structural support and heating element. When electrical current is applied, the conductive polymeric material generates heat that automatically melts ice and snow on the sensor surface, eliminating the need for manual clearing operations.
Solution Approach 2:
The electrical resistance of the conductive polymeric material changes with temperature (positive temperature coefficient), allowing the material to self-regulate its heating output. As the housing and sensor warm up, the increasing resistance naturally limits the current and heat generation, preventing overheating while maintaining effective defrosting.
2Object-affected harmful factors
If sensors are placed inside the vehicle cabin, then they are protected from external elements, but they cannot be effectively reached by windshield defroster and wiper systems
Solution Approach 1:
The sensor assembly is completely self-sufficient for ice and snow removal. The conductive housing generates its own heat when powered, eliminating dependence on vehicle windshield defroster systems. This self-service capability allows the sensor to be positioned outside the cabin where it needs to be while maintaining protection from elements.
3Ease of operation
If manual clearing is used to remove ice and snow from sensors, then the sensors can be cleared, but there is risk of damage to the sensor and the operation is inconvenient
Solution Approach 1:
The mechanical action of manual clearing (wiping, scraping) is replaced with a thermal field generated by the conductive housing. Electrical current flowing through the material creates heat that gently melts ice and evaporates condensation, eliminating mechanical contact that could damage the sensitive sensor elements.
Solution Approach 2:
The sensor assembly automatically performs its own cleaning function through resistive heating of the housing material, eliminating the need for operator intervention. This self-service operation occurs continuously when powered, maintaining sensor clarity without manual effort.
4Object-affected harmful factors
If additional heating circuits are added to the sensor assembly, then ice and snow can be removed, but the device complexity increases
Solution Approach 1:
The structural housing and heating element functions are merged into a single component. The conductive polymeric material forms both the protective housing structure and the heating element, eliminating the need for separate heating circuits, wires, and control systems that would increase device complexity.
Solution Approach 2:
The conductive polymeric housing material serves multiple functions simultaneously: structural support, electrical insulation (when dry), and heating element. This multi-functionality eliminates the need for additional dedicated heating components and simplifies the overall device architecture.
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 provides an integral defrosting capability for sensors mounted outside the vehicle cabin, ensuring continuous operation by eliminating the need for manual clearing and reducing the risk of damage from ice and snow buildup.
Implementation Method 1
A sensor assembly with a housing made of electrically conductive polymeric material that heats up when an electrical current is applied, melting snow and ice or removing frost and condensation without additional heating circuits
Data Source
AI summary
A sensor assembly configured for use in a motor vehicle is presented. The sensor assembly includes a sensor device such as a camera, LIDAR, RADAR, or ultrasonic transceiver, and a housing that is at least partially formed of an electrically conductive polymeric material. The housing has a pair of electrically conductive terminals connected to the electrically conductive polymeric material. The pair of electrically conductive terminals are configured to be interconnected with an electrical power supply. When the terminals are connected to the power supply, the housing heats to remove snow, ice, frost and/or condensation from the sensor assembly. The sensor assembly is suitable for use with a back-up camera, blind spot warning system, lane departure warning system, adaptive cruise control system and/or autonomous driving control system.