Optical Sensor Housing Heating with Directed Airflow Against Fogging
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Solution Overview
Problem
Existing sensors, particularly optical sensors, face challenges in low temperatures due to impaired electronic and mechanical components, such as fogging of the front window, which affects detection beams and requires inefficient and costly heating solutions that restrict the sensor's field of vision and are not suitable for plastic windshields.
Innovation Solution
A sensor design incorporating a heat source and air guidance means to generate a directed warm air flow through forced convection, allowing targeted heating of individual components and preventing fogging without material restrictions, enabling quick operation at low temperatures and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heating elements are mounted on the windshield to be heated, then the heating efficiency is improved, but the sensor's field of view is restricted
Solution Approach 1:
The patent introduces air as an intermediary medium to transfer heat from the heating element to the windshield. The heating element heats the air, and the warm air flow then heats the windshield indirectly, avoiding direct contact between the heating element and the optical path. This resolves the contradiction by maintaining heating efficiency while preserving the field of view.
Solution Approach 2:
The heating system is segmented into distinct functional components: a heating element, air guidance means (ducts/channels), and the target component (windshield). This segmentation allows the heating element to be positioned away from the optical path while still effectively heating the windshield through controlled air flow, thus maintaining both heating efficiency and field of view.
2Quantity of substance
If heating tracks are applied to the windshield, then the heating coverage is improved, but the heating time is extended
Solution Approach 1:
The patent uses pneumatic principles by employing forced convection through air guidance means (such as fans or blowers) to circulate warm air rapidly across the windshield surface. This active air flow system provides comprehensive heating coverage much faster than passive heat conduction through heating tracks, reducing heating time while maintaining full coverage.
3Reliability
If heating elements are used on plastic windshields, then the heating function is achieved, but the windshield material is compromised
Solution Approach 1:
Air serves as an intermediary heat transfer medium between the heating element and the plastic windshield. This indirect heating method avoids direct thermal contact that could damage the plastic material, while still achieving effective heating of the windshield surface to prevent fogging. The heating element heats the air, and the warm air flow transfers heat to the windshield without compromising its structural integrity.
4Device complexity
If non-directional convection is used to heat components, then the heating simplicity is improved, but the heating precision is reduced
Solution Approach 1:
The housing interior is segmented into different thermal zones using air guidance means (ducts, channels, or baffles). This allows the heating system to target specific components (such as the windshield, sensor lenses, or electronic components) independently, providing precise heating control while maintaining relatively simple system architecture. Each zone can be heated according to its specific requirements.
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 achieves efficient and rapid heating of sensor components, prevents fogging, and allows the use of cost-effective materials, ensuring the sensor operates effectively and efficiently even in low temperatures without vision restriction or material limitations.
Implementation Method 1
A heat source and air guidance means are provided in the housing, by means of which a directed warm air flow is generated, forming a heating means. The directed warm air flow is particularly advantageous when generated by forced convection.
Data Source
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AI summary
The invention relates to a sensor (1) with at least one housing (2) in which sensor components and electronic components are integrated. The sensor components are configured to emit and/or receive detection beams, wherein the detection beams are guided through a front window (18) in a wall of the housing (2). The electronic components are configured to control the sensor components and/or to evaluate sensor signals from the sensor components. A heat source and air guides are provided in the housing (2) by means of which a directed warm air flow (23) is generated, which acts as a heating element.