Sensor Bracket with Integrated Cold Plates for Thermal Management
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Solution Overview
Problem
Autonomous vehicle sensors are susceptible to physical and thermal damage from environmental hazards such as rocks, solar radiation, and moisture, leading to reduced performance and stability, especially as higher performance sensors generate more heat and are exposed to harsh conditions.
Innovation Solution
A sensor bracket with cold plates forming a structural core, providing thermal management through extruded designs with internal flow channels and structural ribs or fins, combined with a housing for physical protection, to maintain sensor performance and integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are mounted on the exterior of autonomous vehicles, then sensors can capture environmental data, but sensors are exposed to heat from solar radiation and environmental hazards which degrades performance and stability
Solution Approach 1:
The patent combines the mounting bracket structure with thermal management functionality by integrating cold plates directly into the bracket. The cold plates are thermally coupled to sensors and have fluid flow channels to actively remove heat, merging mechanical support and thermal management into a single integrated component that protects sensors from thermal exposure while maintaining exterior mounting for environmental data capture
Solution Approach 2:
The cold plates act as intermediary elements between the sensors and the external environment. They provide a thermal interface that conducts heat away from sensors through fluid circulation, serving as a mediator that protects sensors from harmful thermal exposure while allowing sensors to remain positioned for optimal environmental data capture
2Measurement precision
If higher performance sensors are used, then sensor data quality improves, but heat generation increases which damages sensors and degrades performance
Solution Approach 1:
The mounting bracket is merged with active cooling functionality through integrated cold plates that are thermally coupled to high-performance sensors. The cold plates contain fluid flow channels that actively remove heat generated by the sensors, allowing high-performance sensors to operate at their full measurement precision capability without thermal damage or performance degradation
Solution Approach 2:
The patent employs hydraulic cooling through fluid circulation channels integrated into the cold plates. The fluid flow actively transports heat away from high-performance sensors, enabling these sensors to maintain optimal operating temperatures despite generating significant heat during high-precision measurement operations
3Productivity
If sensors are exposed to environmental hazards such as rocks and water, then autonomous vehicle navigation data is collected, but physical damage occurs to sensors
Solution Approach 1:
The patent employs a protective housing or enclosure that acts as a physical barrier between sensors and environmental hazards such as rocks and water. This protective shell allows sensors to remain positioned for environmental data collection while shielding them from physical damage, maintaining both productivity and reliability
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
The solution effectively manages thermal loads and provides structural support, protecting sensors from environmental hazards while maintaining performance, even in harsh conditions, thus ensuring reliable operation of autonomous vehicles.
Implementation Method 1
cold plates forming a structural core... providing thermal management through extruded designs with internal flow channels
Implementation Method 2
extruded designs with internal flow channels... combined with a housing for physical protection, to maintain sensor performance and integrity
Data Source
AI summary
An example sensor bracket assembly can include one or more cold plates forming a core bracket structure, wherein the core bracket structure and the one or more cold plates provide structural support for the sensor bracket assembly; a housing enclosing the core bracket structure; one or more sensor mounts for mounting one or more sensors on the sensor bracket assembly; and one or more attachment portions for attaching the sensor bracket assembly to a body of a vehicle.