Motor Vehicle Sensor Housing with Airflow Clearance
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Solution Overview
Problem
Existing motor vehicle outer wall designs with sensors face issues such as soiling from snow or slush, which reduces signal strength, and large protective plates required to cover sensor fields of view block airflow and increase cooling resistance, weight, and assembly complexity.
Innovation Solution
An outer wall with a sensor device featuring a sensor housing and a protective cover that includes openings or recesses allowing airflow to remove dirt and snow deposits, with a trough-like design and heatable components to prevent ice formation, forming a compact structural unit with snap-lock fastening for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective plate is permanently integrated into the front cover with a large surface area to cover the sensor's field of view, then the sensor is protected from contamination, but the cooling airflow is significantly obstructed, increasing drag and reducing cooling capacity
Solution Approach 1:
The protective plate is segmented into multiple parts: a first protective plate with a first field of view and a second protective plate with a second field of view. This segmentation allows each plate to be optimized for its specific sensing function, reducing the total surface area required while maintaining comprehensive protection. The modular design enables better airflow management compared to a single large integrated plate.
Solution Approach 2:
The patent introduces a vertical dimension to the protective plate design by positioning the sensor at a distance from the front cover surface. This creates a three-dimensional protective structure where the protective plate extends outward, allowing airflow to pass underneath and around the assembly. This dimensional approach reduces the blocking effect on cooling airflow while maintaining effective sensor protection.
2Object-affected harmful factors
If the distance between the sensor and protective plate is increased to prevent snow deposits, then contamination is reduced, but the protective plate must be larger to cover the field of view, requiring higher heating power
Solution Approach 1:
The protective function is segmented between the protective plate structure and the heating element. The plate's geometric design (spacing, angle, and segmentation into first and second plates) provides passive protection against snow accumulation, while the heating element provides active anti-icing only where needed. This segmentation reduces the total heating power required compared to heating a large integrated plate.
Solution Approach 2:
The protective plate is designed with pre-determined spacing and angular orientation from the sensor, creating a geometry that naturally prevents snow deposits before they can reach the sensor. This preliminary geometric configuration reduces reliance on high-power heating elements, as the structure itself mitigates contamination risks.
3Reliability
If the protective plate is integrated into the radiator grille, then the sensor is protected, but the wiring for the heating element becomes complex to route, increasing weight and installation time
Solution Approach 1:
The system is segmented into separable components: the protective plate integrated into the grille structure, and the sensor assembly with heating element as a distinct module. This segmentation allows the heating element wiring to be routed within the sensor housing rather than through the entire grille structure, significantly simplifying installation and reducing wiring complexity.
Solution Approach 2:
The sensor housing serves multiple functions: it protects the sensor, houses the heating element, and provides a mounting interface for the protective plate. This multi-functionality consolidates components that would otherwise require separate mounting and wiring arrangements, reducing overall system complexity.
4Reliability
If a large protective plate is used to cover the sensor field of view, then sensor protection is improved, but the vehicle's drag increases and cooling capacity is reduced
Solution Approach 1:
The protective function is divided between multiple smaller plates (first and second protective plates) rather than one large plate. This segmentation reduces the total surface area required for protection while maintaining comprehensive field of view coverage. The smaller segmented plates create less aerodynamic drag compared to a single large integrated plate.
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 design effectively reduces soiling, maintains airflow, minimizes weight and assembly complexity, and ensures consistent sensor performance by allowing wind to carry away snow and ice deposits while preventing re-freezing, thus enhancing sensor functionality and vehicle efficiency.
Implementation Method 1
a sensor protection cover directed towards the outside of the vehicle, in particular on the front, which is at least partially transparent to signals detectable by the sensor
Implementation Method 2
it is known to heat them
Implementation Method 3
allowing the airflow to pass by the sensor unit integrated into the outer wall, particularly the front cover, at least in certain areas (for example, at the bottom and sides), thus removing and carrying away dirt, water, snow, or even thawed ice from the sensor cover
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A sensor device (2) is designed to be installed in an outer wall, in particular in a front cover (10), of a motor vehicle (1) and is provided with a sensor (22) provided in a sensor housing (20), and a sensor protective cover (24) which is directed to the outside of the vehicle and is transmissive for signals which can be captured by the sensor (22) at least in certain regions. The sensor device is distinguished by the fact that the outer wall, in particular the front cover (10), is provided with an opening (18) or a recess which is designed to accommodate the sensor device (2) and that the clear width of the opening (18) is greater in the width direction and/or height direction of the motor vehicle (1) than the corresponding dimension of the sensor protective cover (24), with the result that a clearance (3) is formed between the edge of the opening (18) or recess and the sensor protective cover (24) in the installed state, which clearance makes it possible for the air stream to flow past the sensor device (2) installed in the outer wall, in particular in the front cover (10), at least in certain regions.