Near-Infrared Sensor Cover with Linear Heater and Anti-Reflection Layer
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Solution Overview
Problem
Existing near-infrared sensor covers require burdensome application processes and suffer from increased reflection and absorption of near-infrared light due to multilayer heater films, leading to reduced detection accuracy and higher manufacturing costs.
Innovation Solution
A near-infrared sensor cover with a transparent resin base, a hard coating layer for increased hardness and impact resistance, a linear heating element for snow melting, and an anti-reflection layer to minimize reflection, eliminating the need for a heater film and simplifying the application process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heater film with OCA adhesive layer is used to melt snow, then snow melting function is achieved, but the application process becomes burdensome and manufacturing complexity increases
Solution Approach 1:
The invention extracts and removes the heater film and OCA adhesive layer from the sensor cover structure. Instead of using a separate heater film that requires application, the snow melting function is integrated directly into the sensor cover through a heater unit with heating elements positioned behind the transparent cover, eliminating the need for adhesive layers and complex application processes while maintaining reliable snow melting capability
Solution Approach 2:
The invention merges the snow melting function with the sensor cover structure itself. The heater unit is integrated into the sensor cover assembly, combining the protective cover and heating function into a single unified structure, thereby eliminating the need for separate heater films and adhesive layers that complicate the application process
2Reliability
If a heater film with multiple layers is used, then snow melting capability is provided, but reflection and absorption of near-infrared light increases
Solution Approach 1:
The invention extracts and removes the heater film structure from the optical path. By positioning the heating elements behind the transparent sensor cover and integrating them into the cover structure rather than using a separate film, the multiple layers that cause reflection and absorption are eliminated, allowing near-infrared light to pass through with minimal interference while maintaining snow melting capability
Solution Approach 2:
The invention applies local quality by positioning heating elements only in specific areas behind the transparent cover where snow accumulation occurs, rather than using a complete heater film that covers the entire surface. This localized heating approach minimizes interference with near-infrared light transmission while providing effective snow melting where needed
3Stability of the object's composition
If OCA adhesive layer is applied to laminate heater film, then heater is attached to base, but manufacturing cost and process complexity increase
Solution Approach 1:
The invention extracts and removes the OCA adhesive layer from the manufacturing process. The heater unit is designed to be integrated directly into the sensor cover structure through mechanical mounting or direct bonding without requiring adhesive films, thereby eliminating the application task and reducing manufacturing complexity while maintaining stable heater attachment
Solution Approach 2:
The invention merges the heater mounting function with the sensor cover manufacturing process itself. By designing the heater unit to be integrated into the cover structure as a unified assembly, the separate adhesive application step is eliminated and the heater attachment is achieved through the combined structure, simplifying manufacturing
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 enhances transmittance of near-infrared light, maintains detection accuracy during snowfall, and reduces manufacturing complexity by eliminating the need for a heater film, while improving durability and weather resistance.
Implementation Method 1
a heater formed at a rear of the base in the transmission direction and formed by a linear heating element that generates heat when energized
Implementation Method 2
an anti-reflection layer formed at a rear of the heater in the transmission direction that limits reflection of near-infrared light
Implementation Method 3
a base formed from a transparent resin material... The base of the cover body is laminated with the heater from the rear in a transmission direction of the near-infrared light
Data Source
Figure 1~2
Figure 3~4
AI summary
A near-infrared sensor cover includes a cover body that is transmissive to near-infrared light. The cover body includes a base, a hard coating layer, a heater, and an anti-reflection layer. The base is formed from a transparent resin material. The hard coating layer is formed at a front of the base in a transmission direction of near-infrared light and has a greater hardness than the base. The heater is formed at a rear of the base in the transmission direction and formed by a linear heating element that generates heat when energized. The anti-reflection layer is formed at a rear of the heater in the transmission direction to limit reflection of near-infrared light.