Vehicle Radome Optical Assembly With Air-Gap Light Guide
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Solution Overview
Problem
Current methods for producing illuminated radome covers for vehicles are complex and costly, requiring separate production and assembly of light guide rings and components, which increases logistics and assembly expenses.
Innovation Solution
A prefabricated optical assembly featuring a one-piece annular cone light guide with a toothed structure, an air gap, and a multilayer lens system that provides homogeneous illumination and minimizes radar wave absorption, integrated with a housing and PCB, allowing for a simplified production and installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate light guide rings and components are produced and assembled, then the illuminated radome cover can be manufactured with modular components, but the production and assembly costs increase
Solution Approach 1:
The patent merges the light guide ring and the radome cover into a single integrated component. The light guide is directly formed as part of the radome cover structure, eliminating the need for separate production and assembly of these components. This integration reduces assembly steps, lowers production costs, and simplifies the overall manufacturing process while maintaining the modular benefit of standardized light guide designs.
2Productivity
If a one-piece annular cone light guide is used, then the assembly process is simplified, but the precision of light distribution may be compromised
Solution Approach 1:
The patent applies local quality by incorporating a toothed structure at specific locations on the light guide's exit surface. These teeth are strategically positioned to collimate and direct light in precise patterns. The one-piece construction maintains overall simplicity and assembly efficiency, while the localized toothed features provide the necessary precision for controlled light distribution without requiring complex multi-component assemblies.
3Illumination intensity
If the light guide exit surface is close to the lenses and films, then the illumination intensity increases, but radar wave transmission is blocked
Solution Approach 1:
The patent introduces an air gap as an intermediary space between the light guide exit surface and the lens/film assembly. This air gap serves as a mediator that allows radar waves to pass through the radome cover without being blocked by the light guide structure. The gap is optimized to maintain sufficient illumination intensity by preserving the light path geometry while enabling electromagnetic wave transmission through the otherwise opaque light guide material.
4Illumination intensity
If decorative lighting functions are added to emblems and front panels, then the aesthetic appeal increases, but the radar sensor performance may be degraded
Solution Approach 1:
The patent segments the radome cover structure into functionally distinct zones: a light-transmissive radome portion for radar sensor operation and an illuminated emblem portion for decorative lighting. The light guide is positioned and configured to illuminate the emblem area without interfering with the radar sensor's field of view through the radome cover. This spatial segmentation allows both decorative lighting and radar functionality to coexist without degrading each other's performance.
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 reduces production and assembly costs by eliminating the need for separate light guide rings and components, while maintaining effective illumination and radar performance, ensuring a cost-effective and efficient manufacturing process.
Implementation Method 1
The light guide is designed as a one-piece annular cone which is attached to the housing with a connection and whose exit surface is spaced away from the arrangement of lenses and films by an air gap
Data Source
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AI summary
Optical assembly (20) comprising a housing (15) with a recess for a radar sensor, equipped with at least one PCB (16) with LEDs (13) and a radome cover (1) with a light guide (2) and an arrangement of lenses (6) and films (7,8), wherein the light guide (2) is designed as a one-piece annular cone which is attached to the housing (15) with a connection and whose exit surface (2b) is spaced apart from the arrangement of lenses (6) and films (7,8) by an air gap.