Overmolded Trim Sensor Lens Assembly
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Solution Overview
Problem
The placement of sensor lens assemblies behind plastic trim components in vehicles reduces the range and optical quality of sensors, and using optical-grade plastic to improve these aspects increases manufacturing costs.
Innovation Solution
A vehicle trim assembly with a lens assembly overmolded into the trim component, using a multi-shot injection molding process, an optical clear adhesive, antireflective coating, and an optical grade infrared transmissive layer, integrated with a sensor module and heat conductive materials to enhance optical quality and reduce material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical-grade plastic is used to improve sensor optical quality and range, then sensor performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using optical-grade plastic only in specific critical areas (lens assembly and immediate sensor vicinity) rather than throughout the entire trim component. The trim component uses standard plastic for non-critical areas, achieving optimal sensor performance while minimizing the quantity of expensive optical-grade material required.
Solution Approach 2:
The patent segments the trim component into distinct zones: an optical interface portion containing the lens assembly where optical-grade plastic is used, and a body portion where standard plastic is used. This segmentation allows differential material selection based on functional requirements, reducing overall manufacturing cost while maintaining sensor performance.
2Device complexity
If sensor lens assembly is placed behind plastic trim component, then integration is achieved, but sensor range and optical quality are reduced
Solution Approach 1:
The patent extracts the lens assembly from the standard plastic trim component and creates a dedicated optical interface portion. This separation allows the lens assembly to be positioned optimally for sensor performance while being integrated into the trim component through overmolding, achieving both integration and optical quality.
Solution Approach 2:
The patent uses composite materials by combining optical-grade plastic for the lens assembly with standard plastic for the trim component body. The multi-shot injection molding process creates a composite structure where each material performs its optimal function, achieving integration without compromising sensor range or optical quality.
3Reliability
If larger quantities of optical-grade plastic are used, then optical quality is improved, but manufacturing cost and material usage increase
Solution Approach 1:
The patent applies local quality by concentrating optical-grade plastic only in the lens assembly and immediate optical path areas. The trim component body uses standard plastic, significantly reducing the total quantity of expensive optical-grade material while maintaining high optical quality where it is most needed for sensor performance.
Solution Approach 2:
The patent segments the plastic material usage into optical-critical areas (lens assembly) requiring optical-grade plastic and non-critical areas (trim body) using standard plastic. This segmentation minimizes the volume of expensive material required while ensuring optical quality is maintained in the functional optical path.
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
This solution allows for the use of smaller quantities of expensive optical-grade plastics while increasing the effective range and optical quality of sensors, reducing manufacturing costs and complexity.
Implementation Method 1
The optical surface of the lens assembly includes an intermediate layer comprising an antireflective coating
Implementation Method 2
The exterior facing surface of the trim component includes a hard coat comprising an optical grade infrared transmissive layer
Implementation Method 3
The lens assembly includes a heat element configured to defog the lens assembly
Implementation Method 4
The trim component includes a heat conductive material configured to cool the lens assembly
Data Source
AI summary
A vehicle trim assembly includes a trim component having an interior facing surface and an exterior facing surface opposite the interior facing surface, a lens assembly overmolded into the trim component, the lens assembly including an optical surface positioned adjacent to the exterior facing surface of the trim component, and a sensor module including a sensor housing enclosing a sensor, the sensor module joined to the trim component and the lens assembly.