Door mounted vehicle sensor

Abstract

A vehicle safety system including a vehicle sensor component integrated into a portion of a vehicle door. A sensing portion may be integrated into a door module. A controller is coupled to the sensor and configured to activate a protective device when required.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.

FIG. 1 depicts a portion of a vehicle in section along with a schematic depiction of a vehicle safety system according to an exemplary embodiment.

FIG. 2 schematically depicts a cross-section of an arrangement for integrating the sensor sensing portion with respect to the vehicle door according to an exemplary embodiment.

FIG. 3 schematically depicts the sensor sensing portion mounted with respect to the vehicle door according to an exemplary embodiment.

FIGS. 4-7 schematically depict configurations for the sensing portion according to several exemplary embodiments.

FIG. 8 schematically depicts one alternative exemplary sensor according to one exemplary embodiment.

FIG. 9 schematically depicts a fastener integrated into the door module according to an exemplary embodiment.

FIG. 10 a depicts a flow chart for injection molding the sensor into the vehicle door according to an exemplary embodiment.

FIG. 10 b schematically depicts a mold cavity or die for manufacturing the door module according to an exemplary embodiment.

Claims

1. A vehicle safety system comprising: a door including a door module;a sensor including a sensing portion configured to detect a vehicle characteristic, wherein the sensing portion is integrated into the door module and wherein the sensing portion is electrically insulated with respect to the vehicle door; anda controller operatively connected to the sensor and configured to activate a protective device when a measurement of the signal received from the sensor indicates the occurrence of a predetermined condition.

2. The safety system of claim 1, wherein the door module comprises a molded plastic.

3. The safety system of claim 1, wherein the sensor is an electromagnetic sensor and the sensing portion is an electrode configured to act as an electromagnetic coil and operative to generate a magnetic flux.

4. The safety system of claim 3, wherein the sensor is configured to function with an exterior portion of the vehicle door so that the exterior portion of the vehicle door provides a path of reluctance for the magnetic flux.

5. The safety system of claim 4, wherein the sensing portion is configured to detect a change in the reluctance of the vehicle door.

6. The safety system of claim 1, wherein the sensor comprises an accelerometer configured to sense the acceleration of the sensing portion.

7. The safety system of claim 1, wherein the sensor includes a strain gauge configured to sense the mechanical stress in the door module.

8. The safety system of claim 1, wherein the sensing portion is integrated into the door module via injection molding.

9. The safety system of claim 1, wherein the door module comprises an electrically insulated polymeric material.

10. The safety system of claim 1, wherein the controller includes a microprocessor configured to determine whether to activate the protective device.

11. The safety system of claim 1, wherein the protective device is an air bag.

12. A vehicle safety system comprising: a door including a door module;a sensor configured to detect a vehicle characteristic;a mounting structure integrated into the door module, wherein the sensor is configured to be connected to the mounting structure after the door module is installed in a vehicle door; anda controller operatively connected to the sensor and configured to activate a protective device when a measurement of the signal received from the sensor indicates the occurrence of a predetermined condition.

13. The vehicle safety system of claim 12, wherein the mounting structure includes an opening for receiving a portion of the sensor.

14. The safety system of claim 12, wherein the sensor includes an electrode configured to act as an electromagnetic coil and configured to generate a magnetic flux.

15. The safety system of claim 14, wherein the sensor is configured so that a current passing through the coil is indicative of the occurrence of a vehicle crash.

16. The safety system of claim 15, wherein the current passing through the coil induces eddy currents in a conductive portion of the vehicle.

17. The safety system of claim 12, wherein the sensor is an accelerometer configured to sense the acceleration of the sensing.

18. The safety system of claim 12, wherein the sensor includes a strain gauge configured to sense the mechanical stress in the door module.

19. The safety system of claim 12, wherein any one of the mounting portion and the door module are composed of an electrically insulated polymeric material.

20. A door module comprising a polymeric material including an embedded electrode forming a sensing portion of a vehicle sensor configured to detect a vehicle characteristic, wherein the electrode is configured to generate an electromagnetic field in the vicinity of the door module.

21. The module of claim 20, wherein the electrode is configured to induce eddy currents in an adjacent conductive vehicle structure and wherein the current through the electrode is indicative of the deformation of the vehicle structure due to a crash involving the vehicle.

22. A method of manufacturing a door module for a vehicle comprising the steps of: providing a die for door module; placing a sensor electrode in the die; injecting a plastic material into the die thereby embedding the electrode into the plastic material; and removing the door module from the die for installation into a door structure of an automobile.