Radar Sensor Plug Connections with Segmented Insulating Plastic

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Solution Overview

Problem

Existing plug connections for radar sensors face challenges in effectively decoupling radar waves from metallic parts and maintaining electrical insulation while allowing for easy and cost-effective production methods.

Innovation Solution

The use of a plastic with radar-absorbent granulate surrounding the plug pins, combined with a thin layer of non-conductive plastic, increases electrical resistance and absorbs radar waves, while maintaining radar-absorbent characteristics, allowing for efficient decoupling of radar waves and easy production through insert-moulding and spraying processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If plug pins are embedded in radar-absorbent plastic, then radar wave absorption is improved, but electrical insulation between plug pins deteriorates

Engineering Contradiction:

Improveradar wave interferenceVSAvoidelectrical insulation

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The plastic housing is segmented into two distinct functional zones: an inner region of non-conductive plastic surrounding the plug pins for electrical insulation, and an outer region of radar-absorbent plastic for electromagnetic wave absorption. This spatial segmentation allows both functions to coexist without interference.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the plastic housing are assigned different material properties: the inner region has high electrical resistivity to insulate plug pins, while the outer region has radar-absorbent characteristics. This local differentiation of material quality enables simultaneous achievement of electrical insulation and radar wave absorption.

Inventive Principle:

Principle #3Local quality

2Reliability

If a two-layer plastic structure is used, then electrical insulation and radar absorption are both improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical insulationVSAvoidplastic structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The non-conductive plastic inner region is formed first as a preliminary structure, with plug pins embedded in it. Subsequently, the radar-absorbent plastic is added as an outer layer. This sequential preliminary action simplifies the manufacturing process compared to creating a complex multi-material mold.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The housing uses a composite structure combining two types of plastic materials: a non-conductive base plastic for electrical insulation and a radar-absorbent plastic containing conductive particles or carbon black for electromagnetic wave absorption. This composite material approach achieves multiple functions while maintaining manufacturing feasibility.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If radar-absorbent plastic is used throughout, then radar wave decoupling is improved, but production cost increases

Engineering Contradiction:

Improveradar wave interferenceVSAvoidproduction cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Instead of using radar-absorbent plastic throughout the entire housing, the invention applies it only partially in the outer region where radar wave absorption is most needed. The inner region uses simpler, less expensive non-conductive plastic, reducing overall material costs while maintaining adequate radar wave decoupling performance.

Inventive Principle:

Principle #16Partial or excessive action

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 enhances electrical insulation and radar wave absorption, increasing electrical resistance between plug pins and maintaining radar-absorbent properties, facilitating efficient and cost-effective production of plug connections for radar sensors.

Implementation Method 1

the plastic which surrounds the plug pins is advantageously at least partially provided with a granulate which absorbs radar waves, such that the electrical impedance of the plastic between the plug pins has a high value in the low-frequency range

Methodology Applied

Scientific EffectRadar wave absorption: Absorption (EM radiation)

Data Source

PatentUS8545266B2Plug connections on radar sensors and method for their production

Publication Date: 2013.10.01 VALEO SCHALTER & SENSOREN GMBH

AI summary

Plug connections on radar sensors include plug pins which are inserted into plastic. The plastic that surrounds the plug pins is at least partially provided with a granulate that absorbs radar waves, such that the electrical impedance of the plastic has a high value in low-frequency range, and the plastic comprises a characteristic which absorbs radar waves in a region of higher-frequency radar waves. The plug pins are surrounded by a thin layer of plastic without radar-absorbent granulate, and a remainder of an area surrounding the plug pins includes the plastic with the granulate which absorbs radar waves.