Vehicle Upper Structure Sensor Cover with External Gap
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Solution Overview
Problem
The existing vehicle upper structures with sensors mounted in the upper portion lack sufficient protection against external forces, as the sensor is only covered by a weak opening member, which can fail to function properly under external impact.
Innovation Solution
A vehicle upper structure design that includes a roof member, a sensor, a sensor cover made of metal, and an external cover with a gap between them, along with a decorative component that allows infrared rays to pass through, providing enhanced protection and functionality for the sensor while maintaining the vehicle's appearance and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sensor is only covered by the opening member, then the vehicle upper structure is simple, but the strength and protection of the sensor is insufficient
Solution Approach 1:
The patent implements a nested cover structure where the sensor cover is positioned inside the opening member, and the external cover is positioned outside the sensor cover. This multi-layer nesting arrangement provides progressive protection for the sensor while maintaining a compact overall structure, resolving the contradiction between strength enhancement and structural complexity.
Solution Approach 2:
The patent divides the protective structure into multiple independent cover components: the opening member, sensor cover, and external cover. Each segment serves a specific protective function and can be independently designed or replaced, allowing the system to achieve high protection strength without excessive overall complexity.
2Strength
If a metal sensor cover is used to protect the sensor, then the protection strength is improved, but the weight of the upper structure increases
Solution Approach 1:
The patent applies metal material specifically to the sensor cover where high strength is most critical for sensor protection, while other components like the opening member and external cover can use lighter materials. This localized application of high-strength material provides necessary protection while minimizing overall weight increase.
Solution Approach 2:
The sensor cover is designed to provide excessive protection strength beyond the minimum requirement, creating a sacrificial protective layer that absorbs impact before it reaches the sensor. This partial over-engineering of the cover allows the use of lighter overall structure while ensuring sensor safety.
3Stability of the object's composition
If the external cover is positioned close to the sensor cover, then the structural compactness is improved, but the waterproofing performance deteriorates
Solution Approach 1:
The patent positions the external cover at a predetermined gap distance from the sensor cover, creating a cushioning air gap before water or other harmful factors can reach the sensor cover. This pre-positioned protective gap prevents direct contact between external contaminants and the sensor assembly, maintaining both compactness and waterproofing.
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 design effectively protects the sensor from external forces by distributing and reducing the impact, improves waterproofing, and ensures the sensor can operate efficiently by allowing infrared rays to pass through, while maintaining the vehicle's appearance and reducing weight.
Implementation Method 1
The sensor is configured to emit and receive electromagnetic waves to recognize an external environment of the vehicle
Implementation Method 2
a decorative component that allows infrared rays to pass through
Data Source
AI summary
A vehicle upper structure includes a roof member of a vehicle, a sensor, a sensor cover, and an external cover. The sensor is mounted on an upper part of the vehicle such that at least part of the sensor is located above the roof member. The sensor is configured to emit and receive electromagnetic waves to recognize the external environment of the vehicle. The sensor cover covers at least the part of the sensor that is above the roof member. The external cover covers the sensor cover from outside with a gap between the external cover and the sensor cover.