EP4449554A1

EP4449554A1 - Radar device arrangement for a vehicle and method to produce a radar device arrangement for a vehicle

Info

Publication number: EP4449554A1
Application number: EP22830794.8A
Authority: EP
Inventors: Yoke Leen SIT; Kevin KRUPINSKI
Original assignee: Valeo Schalter und Sensoren GmbH
Current assignee: Valeo Schalter und Sensoren GmbH
Priority date: 2021-12-13
Filing date: 2022-12-07
Publication date: 2024-10-23
Also published as: DE102021132798A1; WO2023110558A1

Abstract

The invention is concerned with a radar device arrangement (5) for a vehicle, the vehicle with the radar device arrangement (5) and a method to produce the radar device arrangement (5). The radar device arrangement (5) comprises a vehicle component (2) of the vehicle and a radar device. The radar device (6) comprises at least one antenna arrangement (9) and a cover element (8) designed to transmit electromagnetic waves emitted and/or received by the at least one antenna element (9) through the cover element (8). The vehicle component (2) and the cover element (8) are constructed in one piece so that a cover element surface (15) of the cover element (8) is integrated into a vehicle component surface of the vehicle component (2). Therefore, the cover element (8) is molded, preferably injection molded, into the vehicle component (2) of the vehicle.

Description

Radar device arrangement for a vehicle and method to produce a radar device arrangement for a vehicle

The invention is concerned with a radar device arrangement for a vehicle. The radar device arrangement comprises a vehicle component of the vehicle and a radar device. The radar device comprises at least one antenna element and a cover element. The cover element is designed to transmit electromagnetic waves through the cover element. The at least one antenna element is arranged adjacent to the cover element. The invention furthermore is concerned with a vehicle with such a radar device arrangement. Besides, the invention is concerned with a method to produce such radar device arrangement for a vehicle.

A vehicle can comprise a radar device as a detection system to determine a distance, an angle or a velocity of an object in the surroundings of the vehicle in relation to the radar device. The radar device typically comprises a transmitter producing electromagnetic waves in the radio or microwave domain, at least one transmitting antenna, at least one receiving antenna, a receiver and a processor. Radio waves transmitted by the radar device are reflected by the object in an environment of the vehicle. The back signal, meaning the reflected radio waves, is received by the radar device and gives information about the object’s location and speed. The word “radar” is an abbreviation and stands for radio detection and ranging.

Data on the object in the environment of the vehicle provided by the radar device can be used by a driver assistance system such as a lane assistant. However, in order to provide reliable radar data for the driver assistance system, the antennas of the radar device should be arranged accurately within the vehicle so that losses in a radiation pattern of the antennas can be avoided.

US 2017/0160385 A1 discloses a vehicle part having an integrated sensor for detecting the surroundings of a vehicle. The vehicle part is embodied as a plastic part, and at least one sensor is embedded in the plastic material of the vehicle part.

It is the object of the invention to provide a solution to reduce losses in a radiation pattern of antennas of a radar device for a vehicle. The object is solved by the subject matter of the independent claims.

A first aspect of the invention relates to a radar device arrangement for a vehicle.

The invention is based on the observation that a radar device for a vehicle typically comprises a housing within which at least one receiving antenna and at least one transmitting antenna are arranged. The housing comprises a cover element designed to transmit electromagnetic waves emitted and/or received by the at least one antenna through the cover element. The cover element is hence supposedly invisible to the electromagnetic waves transmitted and/or received by the radar device. The cover element is typically arranged in front of the antennas and it may be referred to as radar dome or radome. Other parts of the housing may be produced out of plastic or metal, for example, to provide metal cooling fins for a back cover of the housing. The back cover is preferably arranged opposite the cover element. The other parts may be designed to shield or to only partially transmit electromagnetic waves emitted and/or received by the at least one antenna. Hence, a material of the cover element may differ from a material of the other parts of the housing.

Typically, the material of the cover element has a material permittivity and dielectric constant, which are in a material permittivity range and dielectric constant range typical for radar usage. Therefore, the material of the cover element is supposedly invisible to the electromagnetic waves. Due to this, it tends to be bulky in shape. However, the shape of the cover element influences the shape of the radar device. Therefore, a shape of the radar device is designed in a way that it is difficult to integrate the radar device into a vehicle component of the vehicle. The vehicle component is particularly a front area component, a side area component, a top area component, a bottom area and/or a rear area component of the vehicle, for example a bumper, a headlamp, a side mirror, a pillar and/or a cladding of the vehicle.

A side of the cover element facing away from the at least one antenna typically faces a vehicle component, for example a bumper of the vehicle, if the radar device is arranged in the vehicle. Both the cover element and the vehicle component spatially separate the at least one antenna of the radar device from an environment of the vehicle which is to be monitored by the radar device. As the radar device is typically arranged behind the vehicle component, a shape of the cover element is typically adapted to a shape of a surface of the vehicle component facing the cover element. The surface of the vehicle component is typically curved, so the cover element may be convex in shape. Alternatively, the cover element is flat in shape. No matter the shape of the cover element, there is always at least a small gap between the cover element and at least one antenna of the radar device. Usually, there is also at least a small gap between the cover element and the vehicle component. Due to the gaps, internal reflection of the electromagnetic waves usually occurs, which leads to losses in the radiation pattern of the at least one antenna. Furthermore, there is typically a discontinuity in radiation pattern at edges of the cover element where the cover element adjoins the other parts of the housing. In summary, the gaps as well as the discontinuity result in a degradation of radiation pattern, meaning an intensity of the radiation pattern, meaning an intensity of the transmitted and/or received electromagnetic waves, is decreased compared to an intended radiation pattern. Besides, signal amplitudes and phases may be distorted at the edges. To reduce losses in the radiation pattern of antennas of a radar device, the gaps between the antennas and the cover element should be eliminated.

The inventive radar device arrangement comprises a vehicle component of the vehicle and a radar device. The vehicle component is preferably an exterior component of the vehicle, for example, a front area component and/or a rear area component of the vehicle. The vehicle component may alternatively be referred to as fascia of the vehicle. The fascia is typically a soft area of a front or a rear of a vehicle. The fascia comprises components arranged at a front end, a rear end, a side and/or a top and hence at a front area, rear area, side area and/or top area of the vehicle. This means that the vehicle component of the vehicle is particularly a bumper, a light fixture, for example a headlamp and/or a tail lamp, a side mirror and/or a pillar of the vehicle. The vehicle component can be a decorative component positioned between the radar device and the exterior of the vehicle. The vehicle component can be made of plastic and/or glass.

The radar device comprises at least one antenna element. An antenna element in the sense of the invention may be an antenna. Preferably, the radar device comprises four transmitting antennas and four receiving antennas. The radar device hence preferably comprises multiple antenna elements. The radar device furthermore comprises a cover element. The cover element is designed to transmit electromagnetic waves emitted and/or received by the at least one antenna element through the cover element. In other words, it is designed to allow transmission of the electromagnetic waves relevant to the operation of the radar device. The electromagnetic waves are preferably waves in the radio or microwave domain which are transmitted by the at least one antenna element or received by the at least one antenna element. The cover element may be part of a housing or a complete housing of the radar device.

The at least one antenna element is preferably arranged adjacent to the cover element, wherein at least the cover element spatially separates the at least one antenna element from the environment which is to be monitored by the radar device. This means that the electromagnetic waves transmitted or received by the at least one antenna element always pass through the cover element. The cover element hence faces on one side the at least one antenna element and on an opposite side it at least indirectly faces the environment of the vehicle. This means that the at least one antenna element is preferably positioned next to the cover element so that radar waves transmitted or received by the at least one antenna pass through the cover element but not through other components of the radar device. Preferably, the radar device is mounted in a vehicle, for example in a front area component of the vehicle, such as the bumper. In other words, the inventive radar device is preferably an automotive radar device.

The cover element of the radar device and the vehicle component of the vehicle are constructed in one piece. In other words, the cover element is completely integrated into the vehicle component of the vehicle during its production. More precisely, the vehicle component and the cover element are constructed in one piece so that a cover element surface of the cover element is integrated into a vehicle component surface of the vehicle component. The cover element surface is preferably in one plane with the vehicle component surface. The cover element surface hence is embedded into the vehicle component surface. The cover element may be designed as a window within the vehicle component meaning that the vehicle component comprises a part in which it is not filled with a vehicle component material but with the cover element. If the vehicle component is, for example, a bumper and/or a front cover of a headlamp, the cover element surface may be a relatively small area compared to the vehicle component surface, for example, a surface of the bumper. The vehicle component material is preferably plastic.

There is no interface between the cover element of the radar device and the vehicle component of the vehicle through which electromagnetic waves are transmitted, which are emitted and/or received by the at least one antenna element, because the cover element surface is in one plane with the vehicle component surface. Figuratively viewed, the vehicle component comprises a hole and in this hole the cover element of the radar device is arranged. In other words, the hole or window in the vehicle component is filled with the cover element. As the at least one antenna element is arranged adjacent to the cover element, radio waves or microwaves transmitted and received by the at least one antenna element only pass through the cover element and not through the vehicle component of the vehicle. Therefore, at least one of the gaps, more precisely the gap between the cover element of the radar device and the vehicle component of the vehicle, has been eliminated. Therefore, the radar device arrangement reduces at least partially the losses in radiation pattern of the at least one antenna.

Preferably, the cover element does not protrude beyond the vehicle component. Hence, the cover element surface is flush with the vehicle component surface. There is preferably no gap between the cover element and a part of the vehicle component surrounding the cover element. Preferably, there are no such gaps in all three directions, meaning in a height, width and length direction of the vehicle component.

The radar device is preferably comprised by a vehicle. The vehicle may comprise multiple radar devices. The multiple radar devices can face different parts of an environment of the vehicle, particularly a part of the environment adjacent to at least a part of a front, rear, side, top and/or bottom area of the vehicle. Multiple radar devices can face, for example, the same part of the environment.

A preferred embodiment comprises that the cover element is molded into the vehicle component. The material of the cover element, which is specified as a material that allows transmission of electromagnetic waves, at least of radio waves and microwave, is hence molded into the vehicle component of the vehicle, for example, into the bumper or the front cover of the headlamp. The cover element is hence made with optimal material permittivity and dielectric constant for the intended radar usage, for example, for focusing of the radiation pattern. The used molding technique is preferably injection molding. It is hence possible to construct the cover element and the vehicle component easily in one piece. This kind of one-piece component is particularly cost-effective and time-saving in production, because the manufacture of the radar device arrangement is at least partially based on the common production technique of molding.

According to a further embodiment, the cover element is a radar dome of the radar device. Alternatively, the radar dome can be referred to as radome. The radar dome is always made of a material that allows transmission of electromagnetic waves, meaning in this case radio waves and microwave, through it. The radar dome is a particularly useful cover element for the radar device, as the at least one antenna element can then be integrated into a housing of the radar device, wherein the housing of the radar device typically includes the radar dome on at least one side of the housing. The cover element is hence part of a typical housing of the radar device so that the at least one antenna element can be protected against ingress of dust and water.

Besides, an embodiment comprises that the cover element extends from a first side to a second side of the vehicle component. The first side and the second side are arranged opposite to each other. The first side may be a side facing towards the vehicle when the radar device arrangement is positioned in a preferred mounting position in the vehicle. If the cover element was not integrated into the vehicle component, the radar device would be positioned facing the first side of the vehicle component. However, as described above, the inventive radar device arrangement comprises the integration of the cover element, which is a component of the radar device, into the vehicle component. The inventive radar device arrangement comprises hence, that at least a part of the radar device is arranged within the vehicle component.

The second side of the vehicle component is typically a side facing the environment, of the vehicle. The first and second side are arranged parallel to the vehicle component surface. Preferably, the second side is in one plane with the vehicle component surface. Typically, radio waves or microwaves transmitted by the at least one antenna element pass through the cover element from the first side towards the second side. Radio waves or microwaves received by the at least one antenna element pass through the cover element from the second side towards the first side. Preferably, the first and second side are opposite to each other in a depth direction of the vehicle component. The window within the vehicle component thus is filled completely with the cover element. This allows for a particularly robust design of the radar device arrangement because there are no protruding parts of the cover element relative to the vehicle component.

Moreover, an embodiment comprises that the radar device arrangement comprises a holder element. The holder element may be referred to as a holder or a bracket. The holder element is at least partially arranged on a part of an inner cover element surface that is arranged in one plane with the first side of the vehicle component. The holder element is hence not positioned within the hole or window in the vehicle component, but is added to the cover element and hence preferably protrudes from both the vehicle component and the cover element. It is possible that the holder element is completely positioned on the surface of the cover element. Alternatively or additionally, it is possible that the holder element is at least partially covering the surface of the first side of the vehicle component surrounding the cover element. In other words, the holder element may extend to an adjacent surface area of the first side of the vehicle component in the surroundings of the cover element.

The holder element may be shaped as a pocket. The holder element preferably comprises an open side to insert at least one further components of the radar device, for example, the at least one antenna element. Hence, a function of the holder element is to provide a holding function for further components of the radar device. The holder element is hence particular useful to arrange the at least one further component of the radar device close to the cover element, particularly the inner cover element surface.

A preferred embodiment comprises that the at least one antenna element is electronically connected to a printed circuit board (PCB). The at least one antenna element is positioned on the PCB. Preferably, it is arranged directly on the PCB. The PCB and the at least one antenna element are attached to the cover element by the holder element. The PCB can alternatively be referred to as processing board of the radar device. Preferably, all antenna elements of the radar device are positioned on one PCB. The PCB is preferably inserted into the pocket-shaped holder element on the open side of the holder element, so that the at least one antenna element on the PCB is positioned directly adjacent to the cover element, particularly the inner cover element surface. Preferably, there is no gap between the at least one antenna element and the inner cover element surface. The at least one antenna element and the cover element are hence in direct contact with each other. The holder element preferably fastens the PCB with the at least one antenna element in front the cover element. If there is no gap between the at least one antenna element and the cover element, losses in the radiation pattern are further reduced.

Another embodiment comprises that the PCB is connected to a control unit of the radar device by a connection element. The control unit and the PCB are arranged spaced apart. In other words, the connection element connects the PCB, which is attached to the at least one antenna element, to the control unit of the radar device. The control unit is preferably an electronic control unit (ECU). That the control unit is arranged distanced from the PCB means that the control unit is spatially separated from the PCB and is not directly positioned on and hence not directly electronically connected to the PCB.

If the holder element comprises an open side or another kind of opening, the connection element can be positioned at the open side or the opening, respectively, so that, for example, there is enough space and/or no obstacle for a cable connection between the connection element and the control unit. The control unit comprises preferably at least one microprocessor and/or microcontroller. The control unit may alternatively be referred to as ECU for data processing. The control unit is preferably configured to evaluate and analyze data representing transmitted and/or received electromagnetic waves provided by the at least one antenna element.

It is hence not necessary to include all electronic components of the radar device into the PCB. Therefore, the holder element as well as the dimension of the radar device close to the vehicle component of the vehicle can be sized relatively small and still provide all necessary electronic components. This is the case because the electronic components, meaning at least the control unit, may be positioned spaced apart from the cover element.

Preferably, there is a further holder element designed spaced apart and hence distanced from the cover element and the holder element. The further holder element is arranged to attach and/or fixate the control unit as well as possible other electronic components of the radar device safely, for example, on another part of the vehicle component or on another vehicle component, that is preferably located adjacent to the vehicle component.

Another embodiment comprises that the at least one antenna element is connected to a PCB by a connection element, wherein the at least one antenna element and the PCB are arranged spaced apart. In other words, the at least one antenna element is not positioned on the PCB and hence not directly electronically connected to it. The at least one antenna element is attached to the cover element by the holder element. The antenna element may be a three-dimensional antenna that is preferably arranged without gap in front of the cover element, wherein it is in contact with the cover element surface. The connection element can be an interface of the at least one antenna element to a cable that connects the interface to the separate PCB. The PCB is preferably electronically connected to the control unit of the radar device, for example, to the ECU as well as to other electronic components, for example, to a radio frequency (RF) front end. It is hence possible to only position the at least one antenna element with means of the holder element in front of the cover element and to positon all electronic components, even the PCB, spatially separate from the at least one antenna element. Therefore, a spatially distributed and larger arrangement of the radar device is possible, for example, in case of a relatively large antenna element.

A further embodiment comprises that the connection element provides a high-speed connection for data transmittance to the control unit. Due to the high-speed connection, for example, data processing is performable by the control unit. The transmitted data is data collected by the at least one antenna element. Preferably, the connection element comprises a cable that connects the control unit to the PCB. The high-speed connection is thus preferably a wired connection. Alternatively or additionally, the high-speed connection provided by the connection element may be at least partially a wireless connection. The wireless connection may be a wireless local area network (WLAN), a Bluetooth connection and/or a mobile data network. The mobile data network is preferably based on a technology standard for broadband cellular networks, such as long-term evolution (LTE), long-term evolution advanced (LTE-A), fifth generation (5G) or sixth generation (6G). There is hence guaranteed fast data transport between the PCB with the at least one antenna element and the control unit, so that data processing can be carried out promptly.

According to a further embodiment, the at least one antenna element is a planar antenna, particularly a microstrip antenna. More precisely, the at least one antenna element may be a patch antenna. In this case, the at least one antenna element is fixated on the PCB. The patch antenna typically comprises a microstrip patch as well as a microstrip feed with a port to connect the patch antenna, for example, to a circuity of the PCB. The microstrip antenna may consist of multiple patches in a two-dimensional array. A microstrip antenna is a planar antenna that is relatively easy and fast to fabricate making it a suitable choice for the antenna element.

Alternatively or additionally, the at least one antenna element is a three-dimensional antenna, particularly a waveguide antenna. In principle, it is hence possible to include different types of antennas as antenna element into the radar device of the radar device arrangement. Depending on a size and type of antenna chosen, the holder element has to be sized accordingly, so that the holder element may attach the PCB with the respective antenna element to the cover element. The inventive radar device arrangement is hence particularly versatile.

A preferred embodiment comprises that the at least one antenna element is printed on the cover element. In this embodiment, no holder element is required. The at least one antenna element is then designed as a planar antenna, for example, as the microstrip antenna or particularly as the patch antenna. By, for example, three-dimensional printing performed by a three-dimensional printer, the at least one antenna element may be printed directly on the cover element. The at least one antenna element is thus directly attached to the cover element. It is possible to include all necessary electronic components into the printed component if also the PCB, for example, is printed on the at least one antenna element and/or parts of the cover element surrounding the at least one antenna element. Therefore, a particularly small design of the radar device arrangement is possible.

Alternatively or additionally, a foil may be positioned on the PCB, surrounding components of the radar device arrangement and/or directly on the antenna element. The foil may be referred to as covering. At least an edge of the foil can be stuck or glued to the vehicle component in the surroundings of the cover element. The edge of the foil then comprises an adhesive surface. The foil is preferably detachable and can hence be removed from any component of the radar device arrangement, particularly the vehicle component, without destruction. The purpose of the foil is to provide protection from dust and/or water. The detachable foil is preferably air-permeable. There is thus air exchange through the foil possible, for example to provide a cooling function for the at least one component of the radar device arrangement covered by the foil.

Another aspect of the invention is concerned with a vehicle. The vehicle may be a motor vehicle, for example, a passenger vehicle, a truck, a bus, a motorcycle and/or a moped. The vehicle comprises a radar device arrangement as described above. An embodiment of the inventive radar device arrangement as well as a combination of embodiments of the inventive radar device arrangement are as well embodiments of the inventive vehicle.

A further aspect of the invention is concerned with a method to produce a radar device arrangement for a vehicle. The radar device arrangement comprises a vehicle component of the vehicle and a radar device with at least one antenna element and a cover element. The cover element is designed to transmit electromagnetic waves emitted and/or received by the at least one antenna element through the cover element. The at least one antenna element is arranged adjacent to the cover element. The method comprises constructing the vehicle component and the cover element in one piece so that a cover element surface of the cover element (8) is integrated into a vehicle component surface of the vehicle component. Therefore, the method comprises molding the cover element into the vehicle component. A used molding technique is particularly injection molding. The cover element is hence preferably molded into the vehicle component by injection molding. It is hence possible to use a typical and precise working molding technique to provide the cover element and the vehicle component constructed in one piece. An embodiment of the radar device arrangement and a combination of embodiments of the radar device arrangement are as well embodiments of the inventive method, if applicable. Being construction in one piece means that the vehicle component and the cover element cannot be detached from each other without destruction. They are hence firmly connected with each other. The molding process is a single manufacturing process, which can be multi-stage.

Thereby show:

Fig. 1 a schematic representation of a front area of a vehicle with multiple radar devices;

Fig. 2 a schematic cross section of a radar device;

Fig. 3 a schematic representation of a bumper with an included cover element from a first perspective;

Fig. 4 a schematic representation of a bumper with an included cover element from a second perspective;

Fig. 5 a schematic cross section of a radar device arrangement; and

Fig. 6 a schematic cross section of a radar device arrangement covered with a foil.

Fig. 1 shows a vehicle 1 with a vehicle component 2, which is here a front area component of the vehicle 1 . The vehicle component 2 is, for example, a bumper and/or, a headlamp 4 of the vehicle 1 . The vehicle component 2 can be a fascia of the vehicle 1 . The vehicle 1 comprises multiple possible radar device arrangements 5. Each radar device arrangement 5 comprises a radar device 6 as well as the vehicle component 2 of the vehicle 1 . In y- and z-direction in one plane with the bumper 3 and front cover of the headlamps 4, four radar devices 6 are positioned. The radar devices 6 are visible when looking at an exterior of the vehicle 1 as shown in Fig. 1 . It is possible that only one pair of radar devices 6 is comprised by the vehicle 1 , so that for example the two radar devices 6 behind the bumper 3 or the two radar devices 6 behind the front covers of the two headlamps 4 are sufficient to provide radar monitoring of an environment of the front area of the vehicle 1 . Preferably, the vehicle 1 comprises additionally or alternatively radar devices 6 in a rear, side and/or top area component of the vehicle 1 . Preferably, the radar devices 6, which are positioned in the front cover of the headlamps 4, are positioned out of a path of light of the light source of the headlamp 4. Alternatively or additionally, the radar device 6 may be integrated into claddings of the vehicle 1 . Typically, the radar devices 6 are arranged on outer parts in y-direction of the vehicle component 2 so that they are typically located in a curved area of the vehicle component 2. The radar device 6 may be positioned at any other position in the front area component as vehicle component 2 of the vehicle 1 . The positions sketched are only examples.

The vehicle 1 also comprises an interior 7, meaning a cabin of the vehicle 1 . Within the interior 7, the radar device 6 can alternatively or additionally be arranged (not sketched). Alternatively or additionally, the radar device 6 may be integrated into a rear area component of the vehicle 1 , for example a rear bumper 3 and/or a rear light. In general, the radar device 6 is integrated into the vehicle component 2 of the vehicle 1 , wherein the vehicle component 2 is preferably an exterior component, particularly it is the front area component and/or the rear area component.

Fig. 2 shows the radar device 6. The radar device 6 comprises a cover element 8. The cover element 8 is designed to transmit electromagnetic waves emitted and/or received by at least one antenna element 9 through the cover element 8. The cover element 8 can be a radar dome or radome of the radar device 6.

The radar device 6 furthermore comprises the at least one antenna element 9. The at least one antenna element 9 is arranged adjacent to the cover element 8. Preferably, there is no gap between the at least one antenna element 9 and the cover element 8. In this example, four antenna elements 9 are sketched. The number of antenna elements 9 sketched is only an example. The radar device 6 can comprise more or less antenna elements 9. Preferably, the radar device 6 comprises four transmitting antennas as antenna element 9 as well as four receiving antennas as antenna elements 9.

The at least one antenna element 9 is preferably a planar antenna. Preferably, the planar antenna as at least one antenna element 9 is a microstrip antenna, particularly a patch antenna. The at least one antenna element 9 is in direct contact with the cover element 8 but non-destructively detachable from it. Alternatively, the at least one antenna element 9 is printed on the cover element 8 by three-dimensional printing. In case of printing the planar antenna as at least one antenna element 9 on the cover element 8, the entire at least one antenna element 9 is in direct contact with the cover element 8. Particularly, there is no gap between the at least one antenna element 9 and the cover element 8.

The at least one antenna element 9 is electronically connected to a printed circuit board (PCB) 10. It is possible that other electronic components 11 are electronically connected to the PCB 10 directly. In this example, the electronic components 11 are all necessary electronic components 11 of the radar device 6, for example, an electronic control unit (ECU) and a radio frequency (RF) front end, meaning that there are no further electronic components 11 of the radar device 6 necessary to provide full functionality of the radar device 6. The PCB 10 can be printed on the other components of the radar device 6. More precisely, the PCB 10 is printed on the at least one antenna element 9. It is also possible that the PCB 10 is printed on the cover element 8 surrounding the at least one antenna element 9, meaning that it is printed on a part of the cover element 8 that surrounds the at least one antenna element 9.

Fig. 3 shows the bumper 3 when viewed from an environment 17 of the vehicle 1. An area in x-direction in front of the sketched bumper 3 is hence preferably the environment 17, which is both the environment 17 of the vehicle 1 and the environment 17 of the radar device 6. The cover element 8 of the radar device 6 is integrated into the vehicle component 2, which is here exemplarily the bumper 3. The integration takes place during construction meaning that the cover element 8 and the vehicle component 2 are constructed in one piece. Therefore, a cover element surface 15 of the cover element 8 is integrated into a vehicle component surface 2 of the vehicle component 2. Figuratively expressed, the vehicle component 2 comprises a hole or window and the cover element 8 is arranged in the hole or window, respectively. The cover element surface 15 of the cover element 8 is in one plane with the vehicle component surface 20. The vehicle component surface 20 is the surface of the vehicle component 2 on a second side 12 of the vehicle component 2. The second side 12 of the vehicle component 2 is the side facing the environment 17. At the end, meaning after construction of the cover element 8 and the vehicle component 2 in one piece, the vehicle component 2 does not comprise any hole since the hole is filled completely with the cover element 8. The cover element 8 resembles a window within the vehicle component 2.

The cover element 8 is preferably a radar dome of the radar device 6. It is hence produced out of a material that is designed to transmit electromagnetic waves emitted and/or received by the at least one antenna element 9 through the cover element 8. Preferably, the cover element 8 is molded into the vehicle component 2. Therefore, in Fig. 3 a first method step S1 is indicated. This first method step S1 comprises molding the cover element 8 of the radar device 6 into the vehicle component 2 of the vehicle 1 , which is here exemplarily the bumper 3. As molding technique preferably injection molding is used.

Fig. 4 shows the opposite side of the bumper 3. The side of the bumper 3 shown in Fig. 4 is hence a first side 13 of the vehicle component 2 which is opposite the second side 12 of the vehicle component 2. Fig. 4 shows that the cover element 8 extends from the first side 13 to the second side 12 of the vehicle component 2, which is here exemplarily the bumper 3.

The radar device arrangement 5 comprises a holder element 14 arranged at least partially on a part of the cover element surface 15 of the cover element 8. The cover element surface 15 is arranged in one plane with the first side 13 of the vehicle component 2. In this example, the holder element 14 is a bracket or a pocket-like shaped element. The holder element 14 may be a partially open pocket that comprises at least one open side, which is here the upper side in z-direction. The open side is completely or at least partially open. An object may be inserted into the holder element 14 through the open side.

In Fig. 4, a cross-sectional area 16 is marked. This cross sectional area 16 is sketched in Fig. 5.

Fig. 5 shows the radar device arrangement 5 at the cross-section position 16. The cover element 8 completely fills the hole or window within the vehicle component 2 so that the cover element surface 15 is on the first side 13 and on the second side 12 flush with the vehicle component surface 20. The at least one antenna element 9 is here connected to the PCB 10. The PCB 10 with the at least one antenna element 9 is attached to the cover element 8 by the holder element 14. The holder element 14 fixates the PCB 10 with the at least one antenna element 9 in front of the cover element surface 15. The at least one antenna element 9 is particularly a planar antenna, particularly a microstrip antenna, such as a patch antenna, which is positioned on the PCB 10.

Alternatively or additionally, the at least one antenna element 9 may be a three- dimensional antenna, such as a waveguide antenna (not shown here). In this case, the holder element 14 is to be dimensioned respectively, so that the three-dimensional antenna is positioned directly in front of and in contact with the cover element 8, more precisely the cover element surface 15. The PCB 10 is here connected to an external control unit 19 of the radar device 6 by a connection element 18. In this example, the connection element 18 comprises an interface to the PCB 10 and a cable connection to the control unit 19. The control unit 19, which is for example an electronic control unit (ECU), is configured to provide analysis and evaluation of data received by the at least one antenna element 9. The control unit 19 is arranged spaced apart from the PCB 10. The connection element 18 provides a highspeed connection for data transmittance.

Alternatively or additionally, it is possible that the at least one antenna element 9 is not positioned on the PCB 10 but is, for example, directly connected to the connection element 18 (not sketched). Via the connection element 18, data transmittance between the at least one antenna element 9 and the PCB 10 is possible, preferably at high speed. The PCB 10 is arranged spaced apart from the at least one antenna element 9. In this example, the spaced apart PCB 10 is connected to the control unit 19 and/or the control unit 19 is positioned on the PCB 10. Alternatively or additionally to the control unit 19, the other electronic components 11 may be positioned spaced apart from the PCB 10 and/or the at least one antenna element 9. The other electronic components 11 might be a radar frequency (RF) front end.

Alternatively or additionally to the embodiment shown in Fig. 5, it is possible that the at least one antenna element 9 is directly printed on the cover element 8 by three- dimensional printing. It is also possible that the PCB 10 is printed on the at least one antenna element 9 and/or surrounding areas of the cover element 8 by three-dimensional printing with a substrate material. The printed antenna element 9 is preferably made of metal. Such three-dimensional printing is particularly relevant or interesting for planar antennas as at least one antenna element 9.

Fig. 6 shows an embodiment with a foil 21 positioned on the PCB 10 as well as surrounding components of the radar device arrangement 5. Besides the additional foil 21 , the embodiment shown in Fig. 6 resembles the embodiment shown in Fig. 5. The foil can alternatively be referred to as covering. Alternatively or additionally, the foil 21 may be positioned directly on the antenna element 9. At least an edge of the foil 21 can be stuck or glued to the vehicle component 2 in the surroundings of the cover element 8. The foil 21 is preferably detachable and can hence be removed from any component of the radar device arrangement 5, particularly the vehicle component 2, without destruction. The purpose of the foil 21 is to provide protection from dust and/or water. The detachable foil 21 is preferably air-permeable. There is thus air exchange through the foil 21 possible, for example to provide a cooling function for the at least one component of the radar device arrangement 5 covered by the foil 21 .

In summary, the invention is concerned with a molded radar dome process in vehicle fascia for minimal-loss radar. The radar material, which is here the cover element material with its specific material characteristics, can be molded into the vehicle’s fascia, meaning the vehicle component 2 of the vehicle 1 . The invention, however, will require the antenna board, meaning the PCB 10, to be separate from the conventional circuitry of the typical radar device 6. Such a modular radar device 6 is possible with a satellite or smart radar concept, where the RF front end is minimal and hence very small in shape. A small PCB 10 is then separate from the antenna elements 9 and can be clipped anywhere behind the molded area. It is then connected via high-speed connections to the ECU, meaning the control unit 19 for data processing. Such small radars are on the rise and are very useful. The antenna elements 9 are the typical radar antennas that are printed on a PCB 10, such as a PCB-antenna or a three-dimensional structure antenna, such as a waveguide antenna. These can be fitted to the molded radar dome, meaning to the cover element 8, with greater accuracy thanks to the holder element 14, which can be referred to as bracket. If the antenna elements 9 are printed, they can be printed directly on the molded radar dome, meaning on the molded cover element 8, for even better radiation efficiency.

The radar dome in bumper 3 or cladding eliminates at least one of the barrier stages that the radar signal will encounter. Time saving in the integration state is achieved because the radar device 6 will be fitted directly while the molds are shaped. Repeatability of design and production is achieved. Production accuracy and time improvement is achieved. Repeatability of antenna radiation results is improved because obstructions from cables and other three-dimensional structures hidden behind the bumper or cladding that can affect the radiation pattern negatively are reduced and result deviations and errors due to the non-linear and non-systematic wave reflections are also reduced. Aesthetic reasons are an overall more compact size for easy integration especially for incabin radars and material permittivity can be chosen to enhance the performance of the radiation characteristics.

Claims

Claims A radar device arrangement (5) for a vehicle (1 ), wherein the radar device arrangement (5) comprises a vehicle component (2) of the vehicle (1) and a radar device (6) with at least one antenna element (9) and a cover element (8) designed to transmit electromagnetic waves emitted and/or received by the at least one antenna element (9) through the cover element (8), wherein the at least one antenna element (9) is arranged adjacent to the cover element (8), characterized in that the vehicle component (2) and the cover element (8) are constructed in one piece so that a cover element surface (15) of the cover element (8) is integrated into a vehicle component surface (20) of the vehicle component (2). Radar device arrangement (5) according to claim 1 , characterized in that the cover element (8) is molded into the vehicle component (2). Radar device arrangement (5) according to any of the preceding claims, characterized in that the cover element (8) is a radar dome of the radar device (6). Radar device arrangement (5) according to any of the preceding claims, characterized in that the cover element (8) extends from a first side (13) to a second side (12) of the vehicle component (2), wherein the first side (13) and the second side (12) are arranged opposite to each other. Radar device arrangement (5) according to claim 4, characterized in that the radar device arrangement (5) comprises a holder element (14) arranged at least partially on a part of the cover element surface (15) of the cover element (8), wherein the cover element surface (15) is arranged in one plane with the first side (13) of the vehicle component (2).

6. Radar device arrangement (5) according to claim 5, characterized in that the at least one antenna element (9) is electronically connected to a printed circuit board (10), wherein the at least one antenna element (9) is positioned on the printed circuit board (10) and the printed circuit board (10) with the at least one antenna element (9) is attached to the cover element (8) by the holder element (14).

7. Radar device arrangement (5) according to claim 6, characterized in that the printed circuit board (10) is connected to a control unit (19) of the radar device (6) by a connection element (18), wherein the control unit (19) and the printed circuit board (10) are arranged spaced apart.

8. Radar device arrangement (5) according to claim 5, characterized in that the at least one antenna element (9) is connected to a printed circuit board (10) by a connection element (18), wherein the at least one antenna element (9) and the printed circuit board (10) are arranged spaced apart and the at least one antenna element (9) is attached to the cover element (8) by the holder element (14).

9. Radar device arrangement (5) according to claim 7 or 8, characterized in that the connection element (18) provides a high speed connection for data transmittance.

10. Radar device arrangement (5) according to any of the preceding claims, characterized in that the at least one antenna element (9) is a planar antenna, particularly a microstrip antenna, and/or a three-dimensional antenna, particularly a waveguide antenna.

11 . Radar device arrangement (5) according to any of the preceding claims, characterized in that the at least one antenna element (9) is printed on the cover element (8).

12. Vehicle (1) with a radar device arrangement (5) according to any of the preceding claims.

13. A method to produce a radar device arrangement (5) for a vehicle (1 ), wherein the radar device arrangement (5) comprises a vehicle component (2) of the vehicle (1 ) and a radar device (6) with at least one antenna element (9) and a cover element 19

(8) designed to transmit electromagnetic waves emitted and/or received by the at least one antenna element (9) through the cover element (8), wherein the at least one antenna element (9) is arranged adjacent to the cover element (8), characterized in constructing the vehicle component (2) and the cover element (8) in one piece so that a cover element surface (15) of the cover element (8) is integrated into a vehicle component surface (20) of the vehicle component (2) by molding (S1 ) the cover element (8) into the vehicle component (2), particularly by injection molding.