Heated Radar Sensor Cover With Internal LED Ring Radome
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Solution Overview
Problem
Radar sensors face integration challenges due to frequency range issues with certain paint colors, and existing radomes either compromise vehicle design or fail in cold temperatures, as they are not optimally radar-permeable and can be impaired by ice formation.
Innovation Solution
A cover element with a film housing molded between a front panel and a carrier plate, connected to a heating plate, which includes a circuit board ring with LEDs, where the light is coupled into the carrier plate via optics within the ring structure, ensuring radar signal passage and providing heating without hindering radar transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the radome is covered with paint or metallic structures to enhance vehicle design, then the aesthetic appearance is improved, but the radar wave transmission is impaired due to high reflectivity
Solution Approach 1:
The radome is divided into multiple layers: a decorative outer layer with paint/metallic structures for aesthetic appearance, and an inner radar-transparent layer that ensures proper radar wave transmission. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the radome are assigned different properties: the outer surface is designed with aesthetic considerations (paint, metallic structures) while the inner region maintains radar transparency. The decorative elements are applied locally in areas that do not interfere with radar beam paths.
2Adaptability or versatility
If the radome is made opaque or with complex structures to match vehicle design, then the aesthetic integration is improved, but the radar signal penetration is reduced
Solution Approach 1:
The solution moves the aesthetic function to a different dimension (the outer decorative layer) while keeping the radar transmission function in the inner dimension. This allows the radome to be aesthetically integrated with vehicle design while maintaining radar signal penetration through the use of transparent or translucent materials in the inner layer.
3Adaptability or versatility
If the radome is installed in freezing temperatures, then the sensor operates in various environmental conditions, but ice formation on the radome surface impairs radar operation
Solution Approach 1:
A heating element is integrated into the radome structure to prevent ice formation before it can impair radar operation. The heating element activates in freezing conditions to maintain the radome surface temperature above freezing, ensuring continuous reliable radar operation in various environmental conditions.
4Ease of manufacture
If electrical components are placed outside the housing for easier installation, then the manufacturing process is simplified, but the radar beam transmission is blocked by external components
Solution Approach 1:
Electrical components (LEDs, circuit board ring, connectors) are nested inside the housing structure rather than being mounted externally. This nesting allows the housing to maintain its radar-transparent properties while still providing access to electrical components through the housing walls for installation and maintenance purposes.
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 allows for radar-permeable and heated radome that maintains vehicle design aesthetics while ensuring proper radar operation in various conditions, including freezing temperatures, by keeping electrical components and light coupling internal to the housing, thus avoiding interference with radar beams.
Implementation Method 1
the carrier plate, which is connected to a heating plate at the rear
Implementation Method 2
a circuit board ring with LEDs and connector is installed in the housing base
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The invention relates to a cover element (1) with a housing of a film (5) molded and injected between a front plate (4) and a carrier plate (6), which serves to represent multidimensional structures, wherein the carrier plate (6) is connected to a heating plate (8) at the rear, characterized in that the housing consists of an annular housing base (2) and an annular housing front (3), and a circuit board ring (8) with LEDs (8b) and connector (8a) is installed in the housing base (2).