Vehicle Radar Radome Overmolding for Protected Heating Contacts

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Solution Overview

Problem

Existing methods for manufacturing radomes for radar devices do not adequately protect contact elements from environmental influences and mechanical damage, and require additional post-processing steps to ensure electrical connectivity and structural integrity.

Innovation Solution

The method involves overmolding contact elements with plastic to secure them within the pre-molding, ensuring fixed anchoring and protection while maintaining electrical accessibility, and using ultrasonic or thermocompression welding to integrate a heating unit, such as a heating wire, for efficient heat distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If contact elements are left exposed for electrical connection, then electrical accessibility is improved, but protection from environmental influences and mechanical damage deteriorates

Engineering Contradiction:

Improveelectrical accessibilityVSAvoidprotection from environmental influences and mechanical damage

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies local quality by differentiating the treatment of different regions of the contact element. The overmolding process selectively covers specific portions of the contact element while leaving the electrical contact regions exposed. This creates zones with different properties: protected zones for structural integrity and exposed zones for electrical functionality, thereby resolving the contradiction between protection and accessibility.

Inventive Principle:

Principle #3Local quality

2Reliability

If contact elements are overmolded completely for protection, then protection from environmental influences and mechanical damage is improved, but electrical accessibility and post-processing requirements deteriorate

Engineering Contradiction:

Improveprotection from environmental influences and mechanical damageVSAvoidelectrical accessibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The overmolding process is designed to apply protection selectively rather than uniformly. The mold geometry and process parameters are controlled to ensure that only non-contact regions are covered with plastic material, while contact regions remain accessible. This localized application of protective material resolves the contradiction by providing protection where needed without compromising electrical functionality.

Inventive Principle:

Principle #3Local quality

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 enhances the structural integrity and electrical connectivity of the radome, reduces post-processing, and extends the service life of the system by protecting the contact elements and heating unit from mechanical and environmental damage.

Implementation Method 1

the at least one contact element is at least partially overmolded with plastic

Methodology Applied

Scientific EffectOvermolding:

Implementation Method 2

heating unit for heating the radome

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

using ultrasonic or thermocompression welding to integrate a heating unit

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 4

using ultrasonic or thermocompression welding to integrate a heating unit

Methodology Applied

Scientific EffectThermocompression welding: Welding

Data Source

PatentUS20250312956A1Method for manufacturing a pre-molding and/or a radome for radar devices for vehicles

Publication Date: 2025.10.09 OECHSLER AG

AI summary

In one aspect, a method for manufacturing a pre-molding and/or a radome for radar devices for vehicles includes forming a pre-molding having at least one contact element for electrically contacting a heating unit for heating the radome. When forming the pre-molding, the at least one contact element is at least partially overmolded with plastic.