LiDAR Sensor Cover with 3D Decoration and Refractive Index Matching
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Solution Overview
Problem
Current LiDAR sensor covers with 3D decorative designs suffer from optical distortions and signal interference due to non-parallel surfaces and scattering, which compromise sensor functionality and image quality.
Innovation Solution
A multi-layer structure with angled surfaces and a refractive index difference of ≤0.1 between layers, featuring a transparent polycarbonate or PMMA base with a thermoplastic intermediate layer that forms a 3D structure, allowing for a compact, low-interference LiDAR sensor cover that maintains sensor functionality while enabling decorative and lighting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a 3D decorative design is implemented on the LiDAR sensor cover, then aesthetic appeal and design freedom are improved, but optical distortions and sensor functionality deteriorate
Solution Approach 1:
The cover is divided into multiple functional layers: a first layer with angled surfaces for 3D decoration, a second layer with parallel surfaces for optical transmission, and an intermediate layer with refractive index matching. This segmentation allows each layer to perform its specific function without interfering with others, resolving the contradiction between aesthetic design and sensor functionality.
Solution Approach 2:
Different regions of the cover have different optical properties. The first layer has angled surfaces specifically in decorative areas while maintaining parallel surfaces in sensor-active areas. The intermediate layer has refractive index matched to both adjacent layers locally, ensuring minimal optical distortion only where decoration is needed.
2Shape
If angled surfaces are used for 3D decoration, then visual appeal is improved, but light scattering and optical distortions increase
Solution Approach 1:
The intermediate layer acts as an optical intermediary between the angled first layer and the parallel second layer. Its refractive index is matched to both adjacent layers, creating gradual optical transitions that minimize scattering and distortions caused by the angled surfaces, while still allowing the 3D decorative effect to be visible.
3Shape
If multiple layers with different refractive indices are used for 3D structure, then decorative effect is improved, but optical interference and signal loss increase
Solution Approach 1:
The refractive index parameter is carefully controlled and matched across the intermediate layer and adjacent layers. By setting the refractive index of the intermediate layer to match both the first and second layers within specific ranges, optical interference and signal loss are minimized while maintaining the 3D structural effect.
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 effectively hides the sensor's 3D structure from ambient light, making it invisible, while allowing it to be visible under illumination, and ensures minimal light scattering, thus preserving sensor image quality and resolution.
Implementation Method 1
the refractive indices of layers b. and c. and of layers a. and c. differ by ≤ 0.1, preferably by ≤ 0.05, more preferably by ≤ 0.04, and further preferably by ≤ 0.03
Data Source
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AI summary
The invention relates to a layered structure comprising a first layer a. with a first planar surface A and a surface A' opposite the first surface A, angled at least over a partial area relative to the first surface A, wherein layer a. comprises a transparent material, preferably glass or a thermoplastic polymer, preferably selected from the group consisting of a polycarbonate, a copolycarbonate, polyester carbonate, PMMA, PET, a polyurethane, a thermoplastic polyurethane or a mixture of at least two thereof; a further layer b. with a first planar surface B and a surface B' opposite the first surface B, angled at least over a partial area relative to the first surface B, wherein layer b.comprising a transparent material, preferably glass or a thermoplastic polymer, preferably selected from the group consisting of a polycarbonate, a copolycarbonate, polyester carbonate, PMMA, PET, a polyurethane, a thermoplastic polyurethane or a mixture of at least two thereof; wherein the layers a. and b. are arranged relative to each other such that the planar surfaces A and B are parallel to each other and the angled surfaces A' and B' face each other and have a corresponding angle profile forming a 3-D structure, and wherein an intermediate layer c. is arranged between the angled surface A' of the first layer a. and the angled surface B' of the further layer b. such that its longitudinal extent follows the angle profile and replicates the 3-D structure, and wherein the refractive indices of layers b. and c. or of layers a. and c.each differ by ≤ 0.1, preferably by ≤ 0.05, more preferably by ≤ 0.04, further preferably by ≤ 0.03, as well as its manufacturing process and a lighting system comprising a layer structure according to the invention.