Heated Optical Sensor Cover for Condensation and Ice Removal
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Solution Overview
Problem
Moisture, such as condensation, frost, and ice, can block the transmission of radiation used by optical sensors in vehicles, reducing their effectiveness.
Innovation Solution
A heated cover for optical sensors, comprising a transparent substrate with a conductive layer and a heater wire, which generates heat to remove condensation and ice, is integrated with the sensor's field-of-view to maintain sensor functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional opaque sensor cover is used, then the sensor is protected from physical damage, but moisture and ice block radiation transmission, reducing sensor effectiveness
Solution Approach 1:
The heating elements (conductive layer and heater wire) are integrated into the sensor cover structure in advance, enabling proactive prevention of moisture and ice accumulation before they block the sensor. The heating system can be activated during adverse weather conditions to maintain the cover surface temperature above freezing, preventing ice formation and ensuring continuous radiation transmission to the optical sensor.
2Reliability
If a transparent cover is used to allow radiation transmission, then sensor effectiveness is maintained, but the cover becomes more susceptible to condensation and ice formation
Solution Approach 1:
The patent changes the temperature parameter of the sensor cover surface by integrating heating elements. The conductive layer and heater wire increase the surface temperature to prevent condensation, frost, and ice formation. This parameter change (temperature elevation) directly addresses the harmful effects while maintaining the transparency of the cover material for uninterrupted radiation transmission.
3Reliability
If heating elements are added to remove moisture and ice, then sensor functionality is maintained in adverse weather, but device complexity increases
Solution Approach 1:
The sensor cover is designed with multi-functionality: it serves as both a protective physical barrier and an active heating element. The conductive layer and heater wire are integrated into the cover structure itself, allowing the single component to perform multiple functions (protection + moisture/ice removal). This reduces the need for separate heating assemblies and simplifies the overall system architecture.
Solution Approach 2:
The heating functionality is merged with the sensor cover structure. The conductive layer is applied to the cover surface, and the heater wire is attached to the cover, combining the protective cover and moisture/ice removal functions into a single integrated assembly. This merging reduces device complexity by eliminating the need for separate heating components and simplifies installation and maintenance.
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 heated cover effectively removes condensation and ice, ensuring continuous sensor operation by maintaining transparency and functionality during adverse weather conditions.
Implementation Method 1
a conductive layer affixed to the substrate overlying a field-of-view (FOV) of the optical sensor and configured to generate heat
Implementation Method 2
a heater wire attached to the substrate and at least partially surrounding the FOV
Implementation Method 3
heated cover for removing condensation, frost, and ice from an optical sensor
Implementation Method 4
heated cover for removing condensation, frost, and ice from an optical sensor
Data Source
AI summary
Example embodiments of a sensor assembly for a vehicle include: an optical sensor; a housing defining an interior chamber for holding the optical sensor; and a heated cover attached the housing and enclosing the interior chamber. In some embodiments, the heated cover includes: a substrate overlying the optical sensor; a conductive layer affixed to the substrate and overlying a field-of-view (FOV) of the optical sensor; and a heater wire attached to the substrate and at least partially surrounding the FOV. In some embodiments, each of the substrate and the conductive layer are transparent at a wavelength of light used by the optical sensor.