Elastic Radome Absorber Mounting for Radar Sensor Tolerance Compensation

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Solution Overview

Problem

Existing radome subassemblies for radar sensors in motor vehicles face challenges in maintaining a defined distance between the absorber and the antenna side of the radar-frequency printed circuit board, which is crucial for optimal sensor performance, while also simplifying the installation process and accommodating production tolerances.

Innovation Solution

The absorber is fastened to the radome using an elastic plastic element that allows it to abut and be pressed against the antenna side of the radar-frequency printed circuit board, ensuring a defined distance and compensating for tolerances through elastic deformation, thus decoupling installation position variations from the absorber's distance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the absorber is fastened directly to the radome using rigid connection, then the installation is simple, but the distance between the absorber and the antenna side cannot be precisely defined and is sensitive to production tolerances

Engineering Contradiction:

Improvedistance between absorber and antenna sideVSAvoidinstallation process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

An elastic plastic element is introduced as an intermediary component between the absorber and the radome. This element serves as a mediator that provides both mechanical support and precise distance definition, while its elastic properties allow it to compensate for production tolerances in the radome and absorber components.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The elastic plastic element changes its physical state through elastic deformation in response to mounting forces. By utilizing the elastic properties of the plastic element, the system transforms rigid distance constraints into flexible, tolerance-compensating elastic connections that maintain precise spacing.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the absorber is fastened to the radome without elastic element, then the structure is simpler, but production tolerances cause distance fluctuations that affect sensor performance

Engineering Contradiction:

Improvesensor performance consistencyVSAvoidradome subassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The elastic plastic element is designed beforehand to compensate for expected production tolerances. By incorporating this elastic cushioning element during manufacturing, the system pre-adapts to potential dimensional variations in the radome and absorber, ensuring consistent absorber-to-antenna distance regardless of manufacturing tolerances.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of operation

If the absorber and radome are installed separately, then positioning precision can be achieved, but the installation process becomes laborious and time-consuming

Engineering Contradiction:

Improveinstallation process easeVSAvoidabsorber positioning accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The absorber and radome are merged into a single pre-assembled radome subassembly with the elastic plastic element already in place. This merging allows the entire unit to be installed as one component, simplifying the installation process while the elastic element ensures precise absorber positioning relative to the antenna side during operation.

Inventive Principle:

Principle #5Merging (Combining)

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 enables precise definition of the absorber's distance from the antenna side, ensuring consistent sensor performance and simplifying the installation process by integrating the absorber and radome as a single subassembly, while accommodating production tolerances without laborious additional steps.

Implementation Method 1

the elastic plastic element can compensate for a distance tolerance between the absorber and the radome

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

an absorber for radar waves in order to shield the radar-frequency printed circuit

Methodology Applied

Scientific EffectRadar wave absorption: Absorption (EM radiation)

Data Source

PatentUS11342659B2Radome subassembly for a radar sensor for motor vehicles

Publication Date: 2022.05.24 ROBERT BOSCH GMBH

AI summary

A radome subassembly for a radar sensor for motor vehicles, which radar sensor encompasses a radar-frequency printed circuit board having at least one antenna and a radar-frequency printed circuit alongside the antenna, the radome subassembly encompassing: a radome for covering the antenna side of the radar-frequency printed circuit board; and an absorber for radar waves in order to shield the radar-frequency printed circuit, the absorber being disposed in front of an inner side of the radome, the absorber leaving a region next to the absorber, in front of the inner side of the radome, open for a main antenna lobe of the at least one antenna, the absorber being fastened on the radome, and the radome subassembly having at least one elastic plastic element by way of which the absorber is braced movably against the inner side of the radome. A radar sensor having the radome subassembly is also described.