Optical Sensor Glass Cover with Thin Wire Heating
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Solution Overview
Problem
Current optical sensor covers in vehicles face challenges with defogging and defrosting, as existing heating systems are either inefficient, bulky, or cause optical disturbances, and can lead to hotspots and poor connection issues, which are not compatible with the need for rapid and homogeneous heating without affecting the sensor's field of view.
Innovation Solution
A glass cover with a pattern of conductive wires positioned within the field of view of the optical sensor, connected to electronic pads outside the field of view for power supply, optimizing wire width and pitch for efficient and homogeneous heating while minimizing optical disturbance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heating wires are placed in the field of view of the optical sensor to rapidly defog/defrost the center of the FOV, then the defrosting speed is improved, but the camera acquisition is disturbed and hotspots are created
Solution Approach 1:
The patent changes the critical parameter of wire diameter from conventional 5-200 μm to a specific range of 1-10 μm. This parameter change allows the heating wires to be thin enough to minimize optical disturbance and avoid hotspots while still providing sufficient heating power for rapid defrosting of the optical sensor cover within the field of view.
Solution Approach 2:
The patent applies local quality by positioning heating wires specifically within the field of view area where rapid defrosting is most critical, while using extremely thin wires (1-10 μm) only in these specific locations. This allows localized high-performance defrosting without creating hotspots or significant optical disturbance in the camera's field of view.
2Power
If heating wires with diameter 5-200 μm are used to provide sufficient heating power, then the defrosting capability is improved, but the wire diameter is too large causing optical disturbance and hotspots
Solution Approach 1:
The patent fundamentally changes the wire diameter parameter from the conventional 5-200 μm range down to 1-10 μm. This parameter change enables the wires to maintain sufficient heating power through high current density while being thin enough to minimize optical disturbance and prevent hotspot formation in the optical sensor's field of view.
Solution Approach 2:
The patent employs extremely thin conductive wire structures (1-10 μm diameter) that function as flexible heating elements. These ultra-thin wires provide the necessary heating power while being sufficiently thin to avoid significant optical disturbance, effectively treating the heating element as a near-two-dimensional structure that minimizes interference with optical transmission.
3Object-affected harmful factors
If the camera position and cover are carefully adjusted to position heating elements out of the FOV, then optical disturbance is reduced, but the defrosting time increases and equipment footprint enlarges
Solution Approach 1:
The patent changes the wire diameter parameter to 1-10 μm, enabling the placement of heating wires directly within the field of view area. This parameter change allows the heating elements to be positioned where they are most effective for rapid defrosting, eliminating the need to position them outside the FOV and thereby reducing defrosting time without causing significant optical disturbance.
Solution Approach 2:
The patent inverts the conventional approach by placing heating wires within the field of view rather than outside it. By using ultra-thin wires (1-10 μm), the patent makes it possible to reverse the traditional positioning strategy, achieving faster defrosting performance while minimizing optical disturbance through the inverted placement configuration.
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 enables rapid and efficient defogging/defrosting of optical sensor covers without significant optical disturbance, reducing the risk of hotspots and improving connection reliability, thus ensuring timely and effective operation of vehicle systems.
Implementation Method 1
The heating system comprises a pattern of wires made of a conductive material positioned in the field of view of the optical sensor on the glass cover
Implementation Method 2
The thermal diffusivity in the PVB is also lower than the one for the glass. That means the thermal gradient is sharp and the heated PVB inhibits a homogeneous heating
Data Source
AI summary
A glass cover for an optical sensor comprising a heating system. The heating system comprises a pattern of wires having a width between 14 and 300 μm, preferably between 25 and 200 μm, more preferably between 35 and 100 μm, even more preferably between 45 and 55 μm. A related sensor device that includes the glass cover as well as a method to obtain the glass cover are also disclosed.