DE202020104648U1 - Vehicle add-on part with integrated sensor module - Google Patents

Abstract

Vehicle add-on part (10) with an integrated sensor module (5), at least comprising:
- A cover (1) with an outer side (I) and an inner side (II), the cover (1) at least partially made of a transparent thermoplastic material,
- A carrier part (6) which is arranged on the inside (II) of the cover (1),
- an indentation (4) of the cover (1) and the carrier part (6) which is set back with respect to the outside (I) of the cover (1),
- A sensor viewing window (2) within the indentation (4),
- A sensor module (5) which is inserted in the area of the sensor see-through window (2) on the inside (II) of the cover (1), the cover (1) and / or the support part (6) having at least one air duct (3) comprise at least one opening (3a) and the opening (3a) points in the direction of the sensor module (5).

Description

The invention relates to an add-on part for a vehicle, also referred to below as a vehicle add-on part or add-on part for short, into which a sensor module is integrated.

Modern vehicle concepts often have powerful driver assistance systems and especially systems for autonomous driving. A complex sensor system is required for this in order to record and evaluate the very extensive environmental data. In addition to radio and radar systems, optical systems are also used here.

For design reasons, it is desirable for the vehicle manufacturer to accommodate this sensor system in or on the vehicle as invisibly as possible to the outside viewer. In the case of camera systems that require a view of the environment in the visual spectrum of light from 380 nm to 780 nm, these are usually cleverly attached behind mineral glass and thus covered or veiled for the viewer under normal lighting conditions.

Depending on the strength and the angle of the light hitting the component surface and the viewing angle, however, there are certain limits to such a concept. Under certain conditions, the assemblies integrated behind a transparent cover can become visible. It is therefore important to make these as small and thus as inconspicuous as possible. In the case of a camera module, these are the camera lens and possibly the fastening elements and cables. A space-saving integration of a sensor module in a vehicle add-on part is for example in WO 2019/081315 A1 described.

In order to ensure that the integrated sensor module functions correctly, the surface of the vehicle add-on part located in the transparent area of the sensor must be kept free of dust particles, moisture and ice. For this purpose, for example, the integration of heatable structures such as heating wires or heatable thin-film systems is conceivable. In US 2018/0284268 A1 and DE 102013223783 A1 buildup of water and ice should be removed using ultrasound. Other solutions are based on the targeted guidance of a stream of air to remove water deposits, such as in DE 2020161 06799 U1 and JP 2018/115943 A disclosed.

The use of air currents offers an effective way of cleaning and de-icing the vehicle add-on part, which is much easier and cheaper to integrate compared to heating structures or ultrasonic-emitting elements. However, precise guidance of the air flows is essential for an effective function. At the same time, the end customer expects a visually appealing appearance in which the integrated sensor module and the means for de-icing the sensor module are optically as inconspicuous as possible.

The object of the invention is to provide a vehicle add-on part with an integrated sensor module in which the see-through area of the sensor is kept free of water and ice buildup and in which the integrated sensor module is as inconspicuous as possible from the outside.

The object of the present invention is achieved according to the invention by a vehicle add-on part with an integrated sensor module in accordance with claim 1.

The add-on part according to the invention comprises at least one cover with an outside and an inside and a carrier part which is arranged on the inside of the cover and in which a sensor module is arranged. The sensor module comprises at least one sensor. The at least one sensor is arranged in the direction of the inside of the cover, so that the beam path to the sensor runs through the cover from the outside. The cover and the carrier part have a common indentation which is set back with respect to the outside of the cover. In this sense, set back means offset from the outside of the cover in the direction of the carrier part. Inside the indentation there is a sensor viewing window which is transparent to the radiation to be detected by the sensor. The sensor module is inserted in the area of the sensor window on the inside of the cover.

As an alternative or in addition to an indentation for the sensor viewing window in combination with air ducts attached in the vicinity of the indentation, protruding elements such as spoilers can also be provided in which the air ducts are introduced.

The cover and / or the carrier part comprise at least one air duct which opens into at least one opening. The at least one opening of the at least one air duct is aligned such that the opening points in the direction of the sensor viewing window. An air flow emerging from the opening is thus directed towards the sensor viewing window. This removes dust and water droplets on the outside of the cover in the area of the sensor viewing window.

The vehicle attachment according to the invention can be used as plastic parts or plastic disc for Automotive exterior applications are used, particularly in the field of ADAS systems. The term ADAS systems refers to modern driver assistance systems that use, for example, environmental sensors based on ultrasound, radar, lidar and / or camera technology. The sensor module according to the invention can comprise one or more of these or other sensors. In order to ensure and improve the performance of the sensor module integrated in the attachment, the attachment according to the invention comprises a ventilation and de-icing system. In doing so, the property of the thermoplastic synthetic material is adopted, which allows ventilation openings or air ducts to be integrated into it in a simple manner. Furthermore, plastics offer the possibility of integrating such air ducts inconspicuously into design elements such as small spoilers or wind deflectors. Plastics are practically not subject to any limitations in terms of shape. The air ducts can be integrated either while the plastic is being shaped, for example in the injection molding process. Alternatively, the air ducts can be drilled afterwards. A nozzle system can be integrated into the air ducts to improve air guidance.

The air flow through the air ducts is preferably generated by means of a fan, for example a radial fan, which can be fed by the vehicle's on-board electronics, the usual 12 V supply voltage being sufficient. An additional heating element is preferably installed between the fan and the air ducts to ensure the de-icing function.

That surface of the cover which faces the external surroundings of the vehicle in the installed position is referred to as the outside. That surface of the cover which, in the installed position, faces the interior of the vehicle is referred to as the inside.

According to the invention, the cover consists at least partially of a transparent thermoplastic material. In addition to the transparent thermoplastic plastic, it can contain, for example, a film, a non-transparent plastic and / or metal parts. In a preferred embodiment, the cover consists entirely of transparent thermoplastic material.

The outside of the cover preferably has essentially the shape of a flat surface, a slightly curved surface or a curved surface. The indentation is set back inwardly in the direction of the carrier part compared to this surface.

In the installed position, the outside of the cover represents the outer skin visible to an observer.

The feature “transparent” relates in the context of the invention to the transparency in the wavelength range relevant for the radiation receiver. For radiation receivers, i.e. Sensors, in the visible range and / or in the infrared range, the transmission for wavelengths from 200 nm to 2000 nm is preferably more than 60%, particularly preferably> 70% and in particular> 90%.

The radiation receiver preferably comprises cameras for visible light of wavelengths from 380 nm to 780 nm and / or infrared light of wavelengths from 780 nm to 1300 nm.

In one possible embodiment, the wavelength range captured by the camera essentially corresponds to the wavelength range visible to the human eye, i.e. 380 nm to 780 nm.

The add-on part according to the invention enables, for example, not only the integration of a driver assistance or accident recording camera in the visible range, but also the integration of an infrared night vision camera, e.g. is designed for track and / or object recognition.

Another advantage of the add-on part according to the invention is that the weight of the cover is significantly reduced compared to a cover made of mineral glass. This is because the cover is at least partially made of transparent thermoplastic material.

In one embodiment, the direction of view of the sensor is not aligned perpendicular to the outer skin of the attachment, but slightly downwards and / or slightly to the side, for example in order to image parts of the road. In this embodiment, the angle between the viewing direction of the sensor and the outside of the cover is less than 90 °, preferably between 85 ° and 30 °, particularly preferably between 85 ° and 50 °, very particularly preferably between 85 ° and 65 °. In a further embodiment, the angle between the viewing direction of the sensor and the outside of the cover is smaller than 90 °, preferably between 89 ° and 30 °, particularly preferably between 89 ° and 65 °, very particularly preferably between 89 ° and 85 °.

Surface structures that can optimize the incidence of light on the sensor, such as, for example, curvatures, prisms or Fresnel optics, can be incorporated into the transparent thermoplastic plastic of the cover. In addition to reducing weight, this represents one Another advantage over the use of mineral glass is that it is not possible to incorporate such surface structures in mineral glass.

The transparent thermoplastic of the cover preferably contains at least polyethylene (PE), polycarbonate (PC), polypropylene (PP), polystyrene, polybutadiene, polynitrile, polyester, in particular polyethylene terephthalate (PET), polyurethanes (PU), polymethyl methacrylates (PMMA), polyacrylates, Polyamides (PA), acrylonitrile-butadiene-styrene copolymers (ABS), styrene-acrylonitrile copolymers (SAN), acrylic ester-styrene-acrylonitrile copolymers (ASA), acrylonitrile-butadiene-styrene-polycarbonate mixtures (ABS / PC) and / or their copolymers, cocondensates and / or mixtures.

The transparent thermoplastic plastic of the cover particularly preferably contains polycarbonates (PC), polymethyl methacrylate (PMMA), styrene-acrylonitrile (SAN), and / or copolymers or mixtures thereof. These polymers allow processing into high-gloss surfaces, some of which are glass-like, depending on the application.

The attachment, in particular the cover, is preferably provided with a protective coating (hardcoat), particularly preferably with thermal or UV-curing lacquers, particularly preferably polysiloxanes, polyacrylates, polymethacrylates, polyurethanes and / or mixtures or copolymers thereof. The hardcoat improves the resistance to mechanical damage, weather conditions, temperature fluctuations, UV radiation and / or aggressive chemicals from the air or splashed water. Optionally, the hardcoat can also perform decorative functions.

The protective coating preferably has a thickness of 1 μm (micrometer) to 50 μm, particularly preferably 2 μm to 25 μm.

Any support part suitable for integrating a sensor module is suitable as a support part. The carrier part optionally comprises a receptacle formed on the carrier part for fixing the sensor module.

In a preferred embodiment, the carrier part is made of thermoplastic material. It preferably contains polyethylene (PE), polycarbonate (PC), polypropylene (PP), polystyrene, polybutadiene, polynitrile, polyesters, polyurethanes, polymethyl methacrylates, polyacrylates, polyesters, polyamines, polyethylene terephthalate (PET), preferably acyl nitrile butadiene styrene (ABS) , Acrylic ester-styrene-acrylonitrile (ASA), acrylonitrile-butadiene-styrene-polycarbonate (ABS / PC) and / or copolymers or mixtures thereof or consists thereof.

The carrier part made of thermoplastic material preferably contains inorganic or organic fillers, particularly preferably SiO ₂ , Al ₂ O ₃ , TiO ₂ , clay minerals, silicates, zeolites, glass fibers, carbon fibers, glass spheres, organic fibers and / or mixtures thereof. These fillers can increase the stability of the carrier part. In addition, the fillers can reduce the proportion of polymeric materials and thus reduce the manufacturing costs of the component.

The thermoplastic plastic, of which the carrier part for the sensor module is made in one embodiment, is preferably opaque, particularly preferably colored, in particular of a dark color, very particularly preferably black.

In one embodiment, the thermoplastic plastic from which the carrier part is made is transparent.

The carrier part made of thermoplastic is preferably 1 mm to 100 mm thick, particularly preferably 2 mm to 50 mm, very particularly preferably 2 mm to 10 mm, in particular 2 mm to 3 mm thick.

The embodiment in which the carrier part is made of thermoplastic as an injection molded part offers the advantage of a simplified installation of the sensor module in the carrier part, since in this case there is a receptacle for the sensor module, fastening elements such as domes, clip openings or the like. and have recesses for cables connected to the sensor module introduced directly into the carrier part designed as an injection-molded part. The sensor module preferably has a counterpart receptacle concept so that, for example, the sensor module can be clipped onto the carrier part in just one step and the fastening elements do not need to be glued. With a cover made of mineral glass, however, the inner shell and fastening elements often have to be additionally glued.

In one embodiment, the cover is designed as an injection molded part made of transparent thermoplastic material. This cover can then be connected to a carrier part described above for the integration of the sensor module.

In a preferred embodiment, the cover and the carrier part are designed as a 2-component injection-molded part.

In an alternative embodiment, the cover is designed as a 1-component injection-molded part with back-molded polymeric film. The back-injected film is preferably opaque, particularly preferably colored, especially dark-colored, whole it is particularly preferably black. A carrier part for the integration of the sensor module can then be attached to the film, ie the carrier part is connected to the film.

The polymeric film preferably contains polycarbonates (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polycarbonate-polybutylene terephthalate (PBT / PC), styrene-acrylonitrile (SAN) and / or copolymers or mixtures thereof.

In one embodiment, the film is colored and / or designed with one or more patterns so that it can bring about an optical effect. There is, for example, the possibility of introducing decorative elements into the attachment via such a film.

The attachment according to the invention can preferably be a front window, a rear window, a side window or a roof window, a strip, in particular a side strip, a front strip, a rear strip or a decorative strip, a bumper, a sill, a spoiler, a lamp cover or a cover, in particular a Pillar trim, particularly preferably a B-pillar trim.

Optionally, the cover and the attached carrier part can be manufactured as a 2-component injection-molded part using the 2-component injection molding process or using the 2-component injection compression molding process with reversible plate technology. These processes enable almost waste-free production because subsequent trimming of the workpiece is not necessary. Complex structures can also be produced directly.

In this case, the cover can either first be manufactured as an injection-molded part and then the carrier part can be injected onto it, or alternatively the carrier part can first be manufactured and then the cover injection-molded onto it.

Optionally, “optical bonding” can be used as a further process step for the production of the add-on part according to the invention, in order to achieve a material bond between the inside of the cover and the camera lens of the sensor. In this process step, a transparent filling compound, preferably with a similar refractive index as the cover and the camera lens or a refractive index that lies in between, is inserted between the camera lens and the cover.

In an alternative method, the cover can be manufactured as a 1-component injection-molded part with a back-molded film. In this method, a film or a film blank is first introduced into that side of the cover injection-molded cavity which later represents the inside of the cover, the film being preferably opaque, particularly preferably colored, in particular dark-colored, very particularly preferably black. The film or the film blank preferably has a local opening in the area where the camera lens will later be located. The film blank is then back-injected with the transparent material, i.e. the injection mold cavity is filled while the film remains in place. The foil blank can be pre-shaped according to the tool contour in order to ensure a better fit and, if necessary, shaping during back injection. A carrier part for integrating a sensor module can then be attached to this cover, or more precisely to the foil blank, the sensor module being arranged in the carrier part in such a way that the camera lens is arranged in the area of the sensor viewing window.

In one embodiment, the film is colored and / or designed with one or more patterns so that it can bring about an optical effect. For example, decorative elements can be introduced into the attachment via such a film.

The motor vehicle add-on part according to the invention is for integrating a sensor module in vehicles, preferably motor vehicles, trucks, buses, in particular for integrating a sensor module in a window, in particular a front window, a rear window, a side window or a roof window, in a strip, in particular a side strip, a front strip , a rear strip or a trim strip, in a bumper, in a sill, in a spoiler, in a lamp cover or in a panel, in particular a pillar panel, particularly preferably in a B-pillar panel.

The invention is explained in more detail below with reference to drawings. The drawings are purely schematic representations and are not true to angle, size or scale. They do not limit the invention in any way.

• 1a zeigt ein Fahrzeuganbauteil 10 als B-Säulenblende für ein Fahrzeug mit einer geometrischen Einbuchtung 4 in der Aussenhaut der Blende ausgehend von der Außenseite I des Fahrzeuganbauteils 1. Innerhalb der Einbuchtung 4 sind sowohl das Sensordurchsichtfenster 2 als auch der bzw. die Öffnungen 3a für den beziehungsweise die Luftkanäle 3 eingebracht. 1b zeigt die Querschnittsansicht A-A' gemäß 1a. Der Luftkanal 3 ist als Durchbruch durch das Trägerteil 6 und die Abdeckung 1 ausgeführt und kann im Spritzgussprozess in die Kunststoffkomponenten 1 und 6 eingebracht oder nachträglich in das fertige Kunststoffteil aus Trägerteil 6 und Abdeckung 1 gebohrt werden. Im Bereich des Sensordurchsichtfensters 2 ist eine Kamera als Sensormodul 5 angeordnet. Das Sichtfeld der Kamera ist bedingt durch die Form der Ausbuchtung 4 in diesem Beispiel leicht nach vorne in Fahrtrichtung gerichtet, was jedoch in vielen Fällen von Vorteil ist. Die Ausbuchtung 4 kann je nach Anwendungsfall auch so ausgeführt sein, dass das Sichtfeld der Kamera leicht nach hinten, oben oder unten gerichtet ist. Der Luftkanal 3 bzw. die Luftkanäle 3 können seitlich oder unter, bevorzugt jedoch über oder schräg über dem Sensordurchsichtfenster 2 angeordnet sein. Letztere Ausführungsart kann einem Wassereintritt in die Luftkanäle vorbeugen. Das Trägerteil 6 ist mit einem Ventilator 8 ausgestattet, der einen Luftstrom 7 durch die Luftkanäle 3 erzeugt.
• 2 zeigt ein Fahrzeuganbauteil 10 gemäß 1a und 1b im Einbauzustand in einem Fahrzeug 20.
• 3 zeigt ein Fahrzeuganbauteil 10 als B-Säulenblende analog 1a und 1b, jedoch mit aus ästhetischen Gründen kreisförmig bzw. elliptisch ausgestalteter Ausbuchtung 4.
• 4 zeigt ein Fahrzeuganbauteil 10 als B-Säulenblende, das im Wesentlichen der Ausführungsform der 1a und 1b entspricht. Im Unterschied dazu ist jedoch die Ausbuchtung 4 hier nicht zu einer Seite hin abgeflacht. Diese Ausführung erlaubt die Ausrichtung des Kamerasichtfeldes senkrecht zur Außenseite I der Abdeckung 1.

Show it:

• 1a shows a vehicle attachment 10 as a B-pillar cover for a vehicle with a geometric indentation 4th in the outer skin of the screen starting from the outside I. of the vehicle attachment 1 . Inside the indentation 4th are both the sensor window 2 as well as the opening or openings 3a for the air duct (s) 3 brought in. 1b shows the cross-sectional view AA 'according to FIG 1a . The air duct 3 is as a breakthrough through the carrier part 6th and the cover 1 and can be used in the injection molding process in the plastic components 1 and 6th introduced or subsequently in the finished plastic part from the carrier part 6th and cover 1 be drilled. In the area of the sensor window 2 is a camera as a sensor module 5 arranged. The camera's field of view is determined by the shape of the bulge 4th in this example it is directed slightly forward in the direction of travel, which is an advantage in many cases. The bulge 4th Depending on the application, it can also be designed so that the field of view of the camera is directed slightly backwards, upwards or downwards. The air duct 3 or the air ducts 3 can be sideways or under, but preferably over or diagonally over the sensor window 2 be arranged. The latter embodiment can prevent water from entering the air ducts. The carrier part 6th is with a fan 8th equipped with an air flow 7th through the air ducts 3 generated.
• 2 shows a vehicle attachment 10 according to 1a and 1b when installed in a vehicle 20th .
• 3 shows a vehicle attachment 10 as a B-pillar trim analog 1a and 1b , but with a circular or elliptical bulge for aesthetic reasons 4th .
• 4th shows a vehicle attachment 10 as a B-pillar cover, which is essentially the embodiment of 1a and 1b corresponds. In contrast, however, is the bulge 4th here not flattened to one side. This design allows the camera field of view to be aligned perpendicular to the outside I. the cover 1 .

List of reference symbols

1

cover

2

Sensor viewing window

3

Air duct

3a

Opening of the ventilation duct

4th

indentation

5

Sensor module

6th

Carrier part

7th

Airflow

8th

fan

10

Vehicle add-on part

20th

vehicle

I.

Outside

II

inside

AA '

Cutting line

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• WO 2019/081315 A1 [0004]
• US 2018/0284268 A1 [0005]
• DE 102013223783 A1 [0005]
• DE 202016106799 U1 [0005]
• JP 2018115943 A [0005]

Claims (7)

Vehicle add-on part (10) with an integrated sensor module (5), at least comprising: - A cover (1) with an outer side (I) and an inner side (II), the cover (1) at least partially made of a transparent thermoplastic material, - A carrier part (6) which is arranged on the inside (II) of the cover (1), - an indentation (4) of the cover (1) and the carrier part (6) which is set back with respect to the outside (I) of the cover (1), - A sensor viewing window (2) within the indentation (4), - A sensor module (5) which is inserted in the area of the sensor see-through window (2) on the inside (II) of the cover (1), the cover (1) and / or the support part (6) having at least one air duct (3) comprise at least one opening (3a) and the opening (3a) points in the direction of the sensor module (5). Vehicle attachment (10) according to Claim 1 , wherein a fan (8) is attached to the inside (II) of the cover (1), which is suitable for generating an air flow (7) through the air duct (3). Vehicle attachment (10) according to Claim 1 or 2 , wherein the vehicle add-on part (10) is a front window, a rear window, a side window, a roof window, a bar, a bumper, a sill, a spoiler, a lamp cover or a panel. Vehicle attachment (10) according to one of the Claims 1 to 3 wherein the carrier part (6) consists of a thermoplastic material, preferably an opaque one, particularly preferably a colored, in particular a dark-colored, very particularly preferably a black thermoplastic material. Vehicle attachment (10) according to one of the Claims 1 to 4th , wherein the cover (1) consists of transparent thermoplastic and preferably the cover (1) and the carrier part (6) are designed as a 2-component injection-molded part. Vehicle attachment (10) according to one of the Claims 1 to 5 , wherein the vehicle add-on part (10) comprises a polymeric film, preferably a back-molded polymeric film, which is preferably arranged between the cover (1) and the carrier part (6) and wherein the film is preferably opaque, particularly preferably colored, in particular dark-colored and whole is particularly preferably black. Vehicle attachment (10) according to one of the Claims 1 to 6th , the cover (1) being coated at least on the outside (I) with a protective coating and the protective coating preferably containing or consisting of at least one polysiloxane, a polyacrylate, a polymethacrylate and / or a polyurethane and the protective layer preferably having a thickness of 1 µm to 50 µm, particularly preferably from 2 µm to 25 µm.

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