阅读说明：本技术 车辆雷达罩及用于制造所述雷达罩的方法 (Vehicle radome and method for manufacturing the same ) 是由 马萨尔·马斯卡罗·荷瑞萨 米克尔·卡萨诺瓦斯·瑟朱艾拉 约瑟·萨纳乌哈·克洛特 马克·博韦尔· 于 2019-08-30 设计创作，主要内容包括：车辆雷达罩包括前层(1)和后层(2),两者均由热塑性材料制成,并且该雷达罩还包括设置于前层(1)的与后层(2)相对的表面上的加热元件(3)。用于制造雷达罩的方法包括：形成前层(1),其中加热元件(3)设置于前层(1)的一表面上；将导电元件(5)设置于加热元件(3)上；形成后层(2)；组装前层(1)和后层(2),使得加热元件(3)位于前层(1)的与后层(2)相对的表面上。本发明提供了具有加热功能和出色外观的雷达罩。(The vehicle radome comprises a front layer (1) and a rear layer (2), both made of thermoplastic material, and a heating element (3) arranged on a surface of the front layer (1) opposite to the rear layer (2). The method for manufacturing the radome includes: forming a front layer (1), wherein the heating element (3) is arranged on a surface of the front layer (1); -arranging an electrically conductive element (5) on the heating element (3); forming a rear layer (2); the front layer (1) and the rear layer (2) are assembled such that the heating element (3) is located on a surface of the front layer (1) opposite the rear layer (2). The present invention provides a radome having a heating function and an excellent appearance.)

1. Vehicle radome comprising a front layer (1) and a rear layer (2), both of which are made of thermoplastic material, characterized in that it further comprises a heating element (3) located on the surface of the front layer (1) opposite to the rear layer (2).

2. Vehicle radome according to claim 1, characterized in that the heating element (3) is a foil with a wire.

3. The vehicle radar cover according to claim 2, wherein the wire is embedded in the foil.

4. Vehicle radome according to claim 2, characterized in that the radome comprises at least one conductive element (5) connected to a wire of the foil.

5. Vehicle radome according to claim 4, characterized in that the electrically conductive element (5) is placed in a recess (4) formed on the heating element (3).

6. The vehicle radome of claim 1 wherein the rear layer (2) includes a housing (6) for a connector.

7. Vehicle radome according to claim 6, characterized in that the housing (6) comprises holes for placing conductive pins (7).

8. Vehicle radome according to claim 4, characterized in that the conductive element (5) is a pad or a base.

9. Vehicle radome according to claim 1, characterized in that both the front layer (1) and the rear layer (2) are provided with recesses and protrusions complementary to each other.

10. Vehicle radome according to claim 1, characterized in that the front layer (1) and/or the rear layer (2) further comprise weldable traces provided along the entire perimeter of the front layer.

11. Vehicle radome according to claim 1 or 5, characterized in that the front layer (1) and/or the rear layer (2) further comprise solderable tracks arranged around the recess (4) for the conductive element (5).

12. A method for manufacturing a vehicle radome of any one of the preceding claims wherein the method comprises the steps of:

-forming the front layer (1), wherein the heating element (3) is arranged on a surface of the front layer (1);

-arranging the electrically conductive element (5) on the heating element (3);

-forming the rear layer (2);

-assembling the front layer (1) and the rear layer (2) with the heating element (3) on the surface of the front layer (1) opposite to the rear layer (2).

13. Method according to claim 12, characterized in that it further comprises the step of arranging said conductive pins (7) on said rear layer (2) before assembling said front layer (1) and said rear layer (2).

14. Method according to claim 12, characterized in that the method further comprises the step of arranging a solderable trace on the front layer (1) and/or the rear layer (12).

15. Method according to claim 12, characterized in that the step of providing the conductive element (5) on the front layer (1) is carried out by soldering.

Technical Field

The present invention relates to a vehicle radome, for example, a decorative radome used as a badge with a metal image, particularly a radome for a radar front face provided in a vehicle front grille, incorporating a heating function. The invention also relates to a method of manufacturing the radome.

Background

Vehicles with sensors capable of sensing the surrounding environment are a key factor in reducing road mortality. By means of the sensors, a driver assistance function is achieved, minimizing the risk and increasing the probability of avoiding collisions.

The vehicle is designed to provide an aesthetically pleasing impression. Therefore, the sensor must be integrated behind the vehicle interior cover to perform its function, hiding it from public view and harmonizing it with the aesthetic design of the vehicle.

For radar sensors, such covers are called radomes. As mentioned above, the radome must minimize its presence from affecting waves transmitted and received by the radar. This is particularly important in severe weather conditions, as driving becomes more dangerous due to reduced visibility, road conditions, etc. Obviously, water, ice and snow constitute a significant risk for the functioning of the radar, since they block the radar waves and can deposit on the radome surface.

Therefore, the radome must be able to remove such layers, e.g. melt them. The integration of heating functions in a decorative radome is a formidable task, considering the complexity of the design, the different materials used and the decorative techniques required to faithfully reproduce the brand identity.

Several inventions have been disclosed for the heated use of automotive radomes.

DE 19724320a1 discloses arranging an electrical conductor track in a curved dielectric body such that the conductive structures do not lie in one plane. The invention does not provide a solution for manufacturing radomes, but only proposes a concept requiring production.

DE 2017055182a1 discloses a flexible printed circuit board injection molded from thermoplastic. Circuit tracks are used instead of wires to carry the current. Electrical contact elements are present in the circuit board so that the plug-in basket can be brought into contact with them.

The main limitation of this invention comes from the fact that circuit tracks are employed, since the performance of radomes using this technology is significantly worse than using wires.

DE 10156699a1 discloses a conductor path which is applied to the rear surface of a plastic part representing a brand logo, which in turn is attached to a second plastic part such that the conductor path is sandwiched between the two plastic materials.

The problem with this invention is the distance between the conductor path and the front surface where ice or snow will be deposited and need to be removed.

US 20060086710a1 discloses a film embedded conductor strip placed in the inner surface of a polymer part. The control unit adjusts the amount of current circulating through the conductor bars to control the heating output. Also, the problem with this invention is the distance between the conductive element and the front surface where ice or snow will be deposited and will need to be removed.

DE102014002438a1 discloses a method for producing a heatable radome, in which a thin foil with grooves in which wires are embedded is formed and insert molded. The electrical contact between the component and the conductor is made at the groove of the membrane.

Although this solution may allow to arrange a foil on the outermost radome surface, optimizing the heat transfer and efficiency, it lacks protection in the contact area. Thus, as the metals in this location are exposed to the environment, they can corrode and degrade over time.

DE102013207482a1 discloses an invention similar to that in DE102014002438a1 and is therefore subject to the same limitations.

The foregoing illustrates design and manufacturing issues affecting heatable radome solutions. The object of the present invention is to solve these problems while providing a pleasant aesthetic and functional solution that is easy to manufacture.

Disclosure of Invention

With the radome of the present invention, the above disadvantages are addressed, and other advantages are provided, as described below.

The vehicle radome of the invention comprises a front layer and a rear layer, both made of thermoplastic material, characterized in that the radome further comprises a heating element, for example a foil with wires, on the surface of said front layer opposite to said rear layer.

Advantageously, the wires are embedded in the foil.

Furthermore, the radome comprises conductive elements connected to the respective wires of the foil, which are preferably arranged in grooves formed on the rear surface of the foil.

In the radome of the invention, the rear layer also preferably comprises a housing for the connector, the housing comprising holes for placing conductive pins.

According to two alternative embodiments, the conductive element is a pad or a pedestal.

Furthermore, in the radome of the invention, both the front and rear layers have recesses and protrusions complementary to each other for optimizing the passage of the radar waves through the radome and for defining the signs of the vehicle.

The front layer and/or the rear layer may further comprise tracks arranged along the entire circumference of the front layer and/or tracks arranged around the recess for the conductive element.

According to a second aspect, the invention also relates to a method for manufacturing the aforementioned vehicle radome, said method comprising the steps of:

-forming the front layer, wherein the heating element, such as a foil with wires, is arranged on a surface of the front layer;

-arranging the electrically conductive element on the heating element;

-forming the rear layer;

-assembling the front layer and the back layer such that the foil is located on a surface of the front layer opposite the back layer.

The method of the present invention may further comprise the steps of:

-providing the conductive pin on the rear layer before assembling the front and rear layers; and/or

-providing solderable tracks on the front and/or rear layer, the step of providing the conductive element on the front layer preferably being performed by soldering.

Furthermore, the formation of the front layer and the back layer is preferably performed by injecting thermoplastic material in the first and second tools.

Disclosed is a radome having a heating function and an excellent appearance. Furthermore, the present invention provides a simple and robust method of connecting the heating element of the radome to an electrical connector, typically located on the innermost surface of the radome, facing the vehicle engine.

For optimal heating performance, the heating elements are placed as close as possible to the outermost surface where water, ice or snow can accumulate.

In several of the inventions described above, the heating element is disposed on the rear surface of the front layer. The thermoplastic material acts as an insulator and therefore the heating element in these cases requires more power to reach a certain temperature than the present invention where the heating element is located directly on the outermost surface.

The invention also prevents corrosion of the electrical contact areas of the foil where the heating wire is embedded, by:

-providing the front layer with a recess on its rear surface,

-surrounding the recess with a thermoplastic material,

-filling the housing on the rear layer with a conductive material,

-eliminating the direct ingress of air and water through the weldable trace around the area.

The invention also optimizes the electrical contact between the heating wire and the connector pins by:

applying a conductive element (e.g. a pad or a base) to the wire accessible through the recess, such that mechanical stress on the embedded thin wire is transferred to the more robust structure of the conductive element,

-filling the housing with an electrically conductive element,

firmly attaching all elements (foil and front and back layers attached) using laser welding.

Drawings

For a better understanding of the above and for the purpose of providing examples only, some non-limiting drawings are given, which schematically depict practical embodiments.

Fig. 1 and 2 are sectional views showing a vehicle radome in a first embodiment according to the present invention; and

fig. 3 is a sectional view of a vehicle radome in a second embodiment according to the present invention.

Detailed Description

A vehicle radome in accordance with a first embodiment of the invention is shown in fig. 1 and 2.

The radome comprises a front layer 1 and a rear layer 2 assembled to each other. Both layers are made of thermoplastic material.

According to the invention, the heating element 3 is arranged on the front surface of the front layer 1, i.e. on the outer surface of the radome.

According to a preferred embodiment, said heating element 3 is a foil (foil) with a plurality of wires, which are preferably embedded in the foil.

The heating element 3 comprises a recess 4 for receiving an electrically conductive element 5, which in this embodiment is a pad 5.

The rear layer 2 comprises a housing 6 for a connector (not shown in the figures) which is directly connected to the power supply of the vehicle. And, the housing 6 includes a conductive pin 7 therein, the conductive pin 7 passing through the housing and a portion of the rear layer 2 through a hole.

Thus, the connection from the connector to the heating element 3 is achieved by the conductive pin 7 and the conductive element 5, so that electricity is transferred from the connector to the respective wires of the heating element 3.

It has to be noted that in the figures only one conductive element, housing and pin is shown for reasons of simplicity, but a radome according to the invention may comprise any suitable number of conductive elements, housings and pins.

Furthermore, in the radome according to the invention, both the front layer 1 and the rear layer 2 have recesses and protrusions complementary to each other for optimizing the passage of the radar waves through the radome and for defining the identity of the vehicle.

The front layer 1 and/or the back layer 2 may preferably also comprise a solderable trace arranged along the entire circumference of the front layer and/or a solderable trace arranged around the recess for said conductive element 5. These conductive traces are not shown in the figure.

A second embodiment is shown in fig. 3, which is very similar to the first embodiment. For the sake of simplicity, the same reference numerals are used to identify the same or equivalent elements.

The main difference with the first embodiment is that the conductive element 5 is a base, which serves as a base for the conductive pin 7.

For optimum heating performance, the heating elements 3 are preferably arranged as close as possible to the outermost surface where water, ice or snow can accumulate.

As mentioned before, for arranging the heating element 3 on the outermost surface of the radome, it is preferred to use a plastic foil, which embeds the wires in a sandwich structure.

It is also possible to place the wires along one or more grooves 4 present on the anterior layer 1 and then inject them twice with the posterior layer 2 (over-injected). This will result in a similar sandwich structure, but the thickness of the front layer 1 will be greater than the foil thickness due to the injection requirements.

The heating element 3 is supplied with power from a connector which is concealed by the emblem body itself. The connector plugs into a cable from the vehicle drive train responsible for providing the electrical energy to be circulated through the heating element 3.

Therefore, the electrical connection between the heating element 3 located on the outermost surface of the radome and the connector located on the innermost surface of the radome must be as simple and reliable as possible.

According to the method of the invention, a heating element 3 is inserted and moulded in a first tool with a first thermoplastic material for forming the front layer 1, the rear surface of the heating element 3 being in direct contact with the front surface of the thermoplastic front layer 1.

The heating element 3 preferably partially covers the front surface of the front layer 1, even though it may be completely covered.

The front layer 1 has a plurality of holes from its front surface to its rear surface at the location of the recess 4, so that the wires embedded in the heating element 3 are accessible from the rear surface of the front layer 1.

Once the moulding of the first part of the radome is completed, a conductive element 5 (such as, but not limited to, a gasket) is placed directly on the recess 4 and soldered to the accessible portion of the embedded wire by ultrasound, pressure, temperature or any other suitable means. Alternatively, the conductive element may be placed prior to the first injection.

Preferably, the number of pads is two and each of the several parallel circuits implemented in the heating element 3 may be at most two pads.

Each pair of pads constitutes a positive and negative potential terminal required for current flow.

As previously mentioned, the front layer 1 also has two projecting or indented tracks on its rear surface, the first one being disposed along the entire perimeter and the second one being disposed around the conductor groove in which the conductive pad is located.

These tracks are required to assemble the front layer 1 and the rear layer 2 together, for example by laser welding.

The back layer 2 is injected in a second tool, the front surface of which has recesses and protrusions complementary to those present in the back surface of the first thermoplastic injection part. This is done to optimize the transmission of radar waves through the radome.

As mentioned before, the rear layer 2 also comprises a housing 6 for embedding the pin 7. The pin 7 will be in electrical contact with the connector from the vehicle and the pin 7 will be in electrical contact with the heating element 3 on the outermost surface of the radome.

Through this connection, electrical energy will circulate from the vehicle driveline to the outermost surface of the radome.

The housing 6 contains a plurality of holes that will fix the position of the pin 7. The hole diameter is smaller than the diameter of the pin 7 but large enough to allow the edge of the pin 7 to be introduced through it.

The insertion of the pins 7 can be performed by a robot which first places the pins 7 in the holes of the housing. The robot then exerts sufficient pressure on the pins 7 to penetrate the rear layer 2 from the front surface to the rear surface. The pin 7 has a flat wide area on a portion protruding from the front surface of the rear layer 2.

As previously mentioned, the rear layer 2 also has two projecting or indented tracks on its front surface, complementary to the tracks present on the rear surface of the first injection part, the first one being placed along the entire periphery and the second one around the housing of the pin.

Once the front layer 1 and the back layer 2 are manufactured as described above, the two components are assembled. By soldering the conductive element 5 and the pin 7 together, the electrical contact between the conductive element 5 and the pin 7 is more robust. The areas of the pins above the front surface of the rear layer 2 are immersed in the conductive UV curable resin or may be filled with a resilient foam or any other suitable means of increasing the stability of the contact between the conductive elements 5 and the pins 7. Thus, a longer life of the radome may be achieved.

Furthermore, the resin or elastic foam fills the housing space in which the conductive element 5 and the pin 7 are to be located, thereby removing air and greatly reducing the possibility of water entering the housing. Thus, the corrosion resistance is significantly improved, which eventually prevents optimal circulation of current from the vehicle connector to the surface to be heated by eroding the conductive area. Thus, a longer life of the heated radome may be achieved.

Then, the front layer 1 and the rear layer 2 are aligned according to their depressions and projections. At the same time, the grooves 4 are aligned with the pin areas.

Laser welding is then applied along a track on the periphery, bringing the rear surface of the front layer 1 into contact with the front surface of the rear layer 2. Laser welding melts the material from both parts and then results in a single strong radome block. Laser welding is also applied on the welding tracks around the housing 6, thereby ensuring the water-tightness of the electrical contact areas.

The front layer 1 and the back layer 2 are then attached. This will also result in a certain amount of pressure between the pin 7 and the heating element wire accessible through the recess 4. Furthermore, by filling the holes in the front layer 1 and the back layer 2 as well as the recesses 4 with the conductive elements 5, the robustness of the electrical contact is greatly improved. Thus, a reliable electrical contact between the pin 7 and the heating element 3 is obtained.

In a second embodiment, the method is very similar.

In this case, the conductive element 5 is formed by a flat base and a projecting member, and they are placed on and fixed to the heating element 3 by ultrasonic welding or any other suitable means. The wire is wound on the protruding member above the base so that the electrical contact is reliably ensured.

While particular embodiments of the present invention have been described, it will be obvious to those skilled in the art that the radome described herein is susceptible to numerous changes and modifications, and that all the details mentioned may be substituted by other technically equivalent ones, without departing from the scope of protection defined by the claims.