Vehicle Roof Sensor Integration With Flush Sealed Window
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Solution Overview
Problem
Existing vehicle roofs with sensor modules positioned on top create an unsatisfactory vehicle appearance, failing to meet customer aesthetic demands.
Innovation Solution
Integrate the sensor module, including an environment sensor, into the roof structure with a sensor cutout in the roof skin assembly, ensuring a sealing and visually integrated design, allowing the sensor window to form a part of the outer roof surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor module is placed on top of the roof skin assembly, then the sensor can detect the vehicle environment effectively, but the vehicle appearance becomes unsatisfactory and does not meet customer aesthetic demands
Solution Approach 1:
The sensor housing is nested within a sensor cutout in the roof skin assembly, with the sensor window forming a visible outer roof surface. This nesting approach allows the sensor module to be integrated into the roof structure rather than placed on top, maintaining aesthetic appearance while preserving detection capability.
Solution Approach 2:
A sealing assembly acts as an intermediary between the sensor housing and the roof skin assembly, enabling the sensor to be integrated into the roof structure while maintaining weatherproofing. This intermediary component allows the sensor window to form part of the outer roof surface without compromising the sealing integrity.
2Shape
If the sensor housing is integrated into the roof skin assembly with a sensor cutout, then the vehicle appearance is optically pleasing and meets customer demands, but moisture and dirt may enter the area below the roof skin assembly
Solution Approach 1:
A sealing assembly is introduced as an intermediary component between the sensor housing and the roof skin assembly. This sealing assembly circumferentially follows the sensor cutout edge and prevents moisture and dirt from entering the area below the roof skin assembly, while allowing the sensor window to form a visible outer roof surface.
Solution Approach 2:
The sealing assembly functions as a flexible sealing element that circumferentially seals the sensor cutout opening. This thin film-like sealing structure prevents harmful factors (moisture and dirt) from penetrating through the integrated sensor housing while maintaining the optical appearance.
3Device complexity
If the sensor window forms a visible outer roof surface, then no separate cover or special adjustment of the roof skin assembly is necessary, but the sensor housing must be precisely integrated into the roof skin assembly
Solution Approach 1:
The sensor housing is merged with the roof skin assembly through a sensor cutout, eliminating the need for separate covers or special adjustments. The sensor window directly forms part of the visible outer roof surface, integrating multiple functions into a unified structure.
Solution Approach 2:
The sealing assembly serves as an intermediary that facilitates the precise integration of the sensor housing into the roof skin assembly. It provides a standardized interface that ensures proper positioning and sealing, reducing the need for high-precision custom adjustments.
Data Source
AI summary
A vehicle roof having a roof skin assembly, a roof substructure, which is disposed below the roof skin assembly, and at least one sensor module having at least one environment sensor for detecting a vehicle environment, the environment sensor being disposed in a sensor housing having a sensor window. The roof skin assembly has a sensor cutout accommodating the sensor housing in a circumferentially sealing manner with the result that the sensor window forms a visible outer roof surface.