LiDAR Cover Material for Surface Quality and Signal Transmission
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Solution Overview
Problem
Existing sensor systems for autonomous driving face challenges with signal attenuation and demolding issues in LiDAR applications, particularly when using conventional materials for covers, which can lead to surface disturbances and reduced accuracy in environmental detection.
Innovation Solution
A sensor system featuring a LiDAR unit with a thermoplastic cover made from a transparent thermoplastic polymer and a monoester of a monocarboxylic acid with 15-20 carbon atoms, free from pentaerythritol-based esters, which provides superior demolding behavior and minimizes signal attenuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thermoplastic cover is used for LiDAR sensors, then manufacturing flexibility and design freedom are improved, but surface quality deteriorates due to demolding issues and adhesion
Solution Approach 1:
The patent modifies the chemical composition parameters of the thermoplastic material by incorporating specific additives and polymers with controlled molecular weights and distributions. This changes the material's physical properties during demolding, reducing adhesion to mold surfaces while maintaining optical clarity and surface finish quality.
Solution Approach 2:
The patent creates a composite thermoplastic material system combining base polymers (polycarbonate, polyethylene terephthalate, polybutylene terephthalate) with functional additives including silicones, oils, and release agents. This composite structure provides both the manufacturing flexibility of thermoplastics and the demolding properties needed for high surface quality.
2Ease of manufacture
If conventional thermoplastic materials are used for LiDAR covers, then manufacturing ease is improved, but LiDAR signal attenuation increases reducing detection accuracy
Solution Approach 1:
The patent carefully controls the chemical composition parameters of the thermoplastic material, limiting specific additives to below certain concentration thresholds (e.g., silicones below 0.1 wt%, certain oils below 0.05 wt%). This parameter optimization ensures the material remains easy to manufacture while minimizing infrared absorption and scattering that would attenuate LiDAR signals.
3Weight of moving object
If thermoplastic covers are used for sensor systems, then weight and shatter resistance are improved, but optical surface quality deteriorates due to adhesion and demolding difficulties
Solution Approach 1:
The patent introduces intermediary substances (release agents, mold release coatings, or surface treatments) that mediate between the thermoplastic cover and the mold surface during manufacturing. These intermediaries prevent direct adhesion, enabling easy demolding while preserving the optical surface quality of the cover.
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 achieves improved surface quality and reduced LiDAR signal attenuation, ensuring high accuracy in environmental detection and supporting the integration of multiple sensor systems for enhanced autonomous driving capabilities.
Implementation Method 1
a cover which is arranged such that IR light emitted and received by the LiDAR unit passes through the cover
Data Source
AI summary
A sensor system comprises a LiDAR unit having a transmitter for laser light having a wavelength of 800 nm to 1600 nm and a receiver for light having a wavelength of 800 nm to 1600 nm, and a cover arranged such that IR light emitted by the LiDAR unit and received by the latter pass through the cover. The cover comprises a layer of a thermoplastic material, wherein the thermoplastic material contains a transparent thermoplastic polymer and a monoester of a monocarboxylic acid having ≥15 C atoms with glycerol or with a monoalcohol having ≥15 C atoms. Furthermore, the thermoplastic material is free of mono-, di-, tri- and tetraesters of stearic acid with pentaerythritol.