Vehicle Radar Sensor Radome Surface Contacts
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Solution Overview
Problem
Existing radar sensor assembly methods for vehicles are cumbersome, particularly in establishing electrical connections between the radar antenna and printed circuit boards, requiring complex insertion of press-in pins and occupying valuable space on the printed circuit board.
Innovation Solution
The radar sensor employs surface contacts between the inner contact sections of the radome and the printed circuit board, utilizing mechanical pressure during assembly to ensure electrical contact without the need for inserting pins, allowing for a more compact design and easier assembly, with the option for elastic contact sections to accommodate tolerances and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press-in pins are used to establish electrical connections between the radar antenna and printed circuit board, then reliable electrical contact is achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent extracts the press-in pins from the assembly process and replaces them with surface contacts integrated into the radome structure. The electrical connection is established through contact surfaces on the radome that directly touch the printed circuit board, eliminating the need for separate pin insertion steps while maintaining reliable electrical contact.
Solution Approach 2:
The patent merges the electrical connection function with the radome structure by integrating contact surfaces directly into the radome. This combines the protective radome function with the electrical connection function, reducing the number of separate components and simplifying the overall assembly process.
2Reliability
If press-in pins are inserted into the printed circuit board to establish electrical connections, then reliable contact is achieved, but valuable space on the printed circuit board is occupied
Solution Approach 1:
The patent removes the press-in pins from the printed circuit board entirely and replaces them with surface contacts on the radome. This extraction eliminates the need for holes and pin insertion, freeing up valuable space on the printed circuit board for other components or traces.
Solution Approach 2:
Instead of inserting connection elements from the printed circuit board side (inward), the patent inverts the approach by placing contact surfaces on the radome (outward side) that contact the printed circuit board from the opposite direction. This inversion eliminates the need for through-holes and preserves printed circuit board space.
3Ease of manufacture
If the printed circuit board is made larger to accommodate press-in pin openings and components, then all connections can be established, but the overall radar sensor size increases
Solution Approach 1:
The patent combines multiple functions into the radome structure: protection, signal transmission, and electrical connection. By integrating the connection surfaces into the radome, the design eliminates the need for separate connection mechanisms that would require additional space on the printed circuit board, thereby reducing the overall radar sensor size.
Solution Approach 2:
The radome is designed with multi-functionality, serving as both a protective cover and an electrical connection interface. This universal design allows the radome to perform multiple functions simultaneously, reducing the need for additional components and minimizing the overall device size.
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 approach simplifies the assembly process, reduces the size of the printed circuit board by eliminating the need for press-in pin openings, and enhances reliability through elastic contact elements that maintain consistent pressure, improving the radar sensor's performance and durability in vehicle applications.
Implementation Method 1
at least one inner contact section can be elastic at least in sections
Data Source
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AI summary
A radar sensor for a vehicle and a method for assembling a radar sensor are described. The radar sensor comprises at least one radar sensor housing in which at least one radar antenna (14) and at least one circuit board (16) are arranged. The radar sensor housing comprises at least one base housing part with a mounting side on which the at least one radar antenna (14) and the at least one circuit board (16) can be inserted, and a radome (24). The mounting side is covered by the radome (24). Signals transmitted by the at least one radar antenna (14) and/or received signals can pass through the radome (24) during operation of the radar sensor.The radome (24) has at least one electrical connecting element (202) which, inside the radar sensor housing, has at least one inner contact section (206) for electrically contacting the at least one circuit board (16) and, outside the radar sensor housing, at least one outer contact section (208) for connecting at least one electrical conductor. At least one inner contact section (206) is designed as a surface contact.