Patent Application
20180159207
The present disclosure generally relates to radomes for vehicles and, more particularly, to a multi-piece vehicle radome having a non-uniform back piece.
The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
A radar cover or “radome” is a structure or enclosure that protects a radar device (e.g., a radar antenna). For vehicle applications, radar devices can be used for object proximity monitoring, such as in adaptive cruise control systems and other similar systems (e.g., parking assistance systems). In addition to not inhibiting or preventing radar accuracy, vehicle radomes are often visible (e.g., mounted to an external surface of the vehicle) and should therefore also be visually appealing.
According to one aspect of the present disclosure, a multi-piece radome for a vehicle is presented. In one exemplary implementation, the radome can comprise one or more front pieces formed of at least a first resin and collectively defining a decorative feature; and a back piece formed of a non-transparent second resin and defining a specific non-uniform thickness for mitigating electromagnetic attenuation through the radome with respect to a radar device.
In some implementations, the one or more front pieces comprise: a cover piece formed of a transparent or translucent first resin and defining a back surface that defines one of a recess and a protrusion; and an intermediary piece defining a front surface that defines the other of the recess and the protrusion, wherein the recess and the protrusion collectively form a first portion of the decorative feature. In some implementations, the intermediary piece is also formed of the transparent or translucent first resin, and the cover piece and the intermediary piece collectively define a uniform thickness.
In some implementations, the radome further comprises a decorative layer applied to at least one of the back surface of the cover piece and the front surface of the intermediary piece, wherein the decorative layer forms a second portion of the decorative feature. In some implementations, the decorative layer comprises at least one of a metalloid applied via physical vapor deposition (PVD), paint, a single or multi-colored film, and a single or multi-colored graphic.
In some implementations, the one or more front pieces comprise a single cover piece defining a back surface that defines a set of recesses; and the back piece defines a front surface that defines a set of protrusions that correspond to the set of recesses, wherein the sets of recesses and protrusions form a portion of the decorative feature. In some implementations, a particular first resin used to form the single cover piece is the same as the non-transparent second resin, and wherein the back piece defines a back surface that defines a linear curvature. In other implementations, a particular first resin used to form the single cover piece is different than the non-transparent second resin, and wherein the back piece defines a back surface that defines a non-linear curvature that defines waves corresponding to the recesses/protrusions.
In some implementations, the specific non-uniform thickness of the back piece is based on at least one of (i) a collective thickness of the cover and intermediary pieces and (ii) a position of a radar device with respect to the radome. According to another aspect of the present disclosure, a system for the vehicle is presented. In one exemplary implementation, the system can comprise the radome; and the radar device arranged at the position with respect to the back piece, the radar device being configured to transmit/receive electromagnetic signals through the radome, wherein at least one of (i) the vehicle has an active safety feature and the vehicle is configured to utilize the system for performing the active safety feature and (ii) the vehicle is an autonomous vehicle or the vehicle has an autonomous driving mode and the vehicle is configured to utilize the system for autonomous driving.
According to yet another aspect of the present disclosure, a method for manufacturing a multi-piece radome for a vehicle is presented. In one exemplary implementation, the method can comprise: molding, using one or more first molds, at least a first resin to form one or more front pieces that collectively define a decorative feature; inserting the one or more front pieces into a second mold; molding, using the second mold, a non-transparent second resin to form a back piece; and removing the radome from the second mold.
In some implementations, the one or more front pieces comprise: a cover piece formed of a transparent or translucent first resin and defining a back surface that defines one of a recess and a protrusion; and an intermediary piece defining a front surface that defines the other of the recess and the protrusion, wherein the recess and the protrusion form collectively form a first portion of the decorative feature. In some implementations, the intermediary piece is also formed of the transparent or translucent first resin, and wherein the cover piece and the intermediary piece collectively define a uniform thickness.
In some implementations, the method further comprises applying a decorative layer to at least one of the back surface of the cover piece and the front surface of the intermediary piece, wherein the decorative layer forms a second portion of the decorative feature. In some implementations, the decorative layer comprises at least one of a metalloid applied via PVD, paint, a single or multi-colored film, and a single or multi-colored graphic.
In some implementations, the one or more front pieces comprise a single cover piece defining a back surface that defines a set of recesses; and the back piece defines a front surface that defines a set of protrusions that correspond to the set of recesses, wherein the sets of recesses and protrusions form a portion of the decorative feature. In some implementations, a particular first resin used to form the single cover piece is the same as the non-transparent second resin, and wherein the back piece defines a back surface that defines a linear curvature. In other implementations, a particular first resin used to form the single cover piece is different than the non-transparent second resin, and wherein the back piece defines a back surface that defines a non-linear curvature that defines waves corresponding to the recesses/protrusions.
In some implementations, the specific non-uniform thickness of the back piece is based on at least one of (i) a collective thickness of the cover and intermediary pieces and (ii) a position of a radar device with respect to the radome. In some implementations, at least one of (i) the vehicle has an active safety feature and the vehicle is configured to utilize the radar device and the radome for performing the active safety feature and (ii) the vehicle is an autonomous vehicle or the vehicle has an autonomous driving mode and the vehicle is configured to utilize the radar device and the radome for autonomous driving.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
Conventional automotive radomes are typically designed to have a uniform thickness. This uniform thickness can decrease electromagnetic signal attenuation (also known as “radar loss” or “angular loss”), while also making the radome relatively easy to design and manufacture. For large scanning angles by the radar device (e.g., +/−˜90 degrees, or ˜180 total degrees), these conventional, uniform thickness radomes still suffer from large radar loss, particularly at larger scanning angles corresponding to large angles of incidence. The term “scanning angle” as used herein refers to a positive or negative angle with respect to dead center with respect to the radar device (e.g., 0 degrees). The term “angle of incidence” herein refers to the angle between an electromagnetic wave incident on a surface and a line perpendicular to the surface at the point of incidence. As shown in plot 100 of
A small scanning range (e.g., less than +/−30 degrees) may be acceptable for certain applications, such as adaptive cruise control where only a vehicle directly in front of the radar device is being scanned for. Larger scanning ranges, however, may be required for other applications. One non-limiting example of an application that would require larger scanning angles is an autonomous vehicle or a vehicle having an autonomous driving mode. It will be appreciated, however, that there may be many other applications, such as any active safety feature of a vehicle (object proximity detection, collision avoidance, active cruise control, parking assistance, etc.). These types of vehicles or vehicle systems may require the ability to accurately scan across a much larger scanning range (e.g., +/−˜90 degrees, or ˜180 degrees). As mentioned above, larger scanning angles typically correspond to larger angles of incidence for the radome, which affects system performance. Additionally, the appealing visual appearance of the radome needs to remain the same, i.e., if a portion of the radome was to be modified. Therefore, there is a need for multi-piece radomes that are both visually appealing while also providing for an increased scanning range by a radar device.
Accordingly, improved multi-piece radomes having a non-uniform back piece and methods of their manufacture are presented. One or more cover/intermediary pieces are also provided on top of or in front of the back piece. The one or more cover/intermediary pieces, however, can have a uniform thickness when together, particularly when formed of the same material. The visual appearance of any decorative features applied to the cover/intermediary piece(s) or designed therein and therebetween can thus be maintained. In other words, these decorative features are still clearly visible to a user as intended by the designer, but the non-uniform back piece can provide for decreased/eliminated electromagnetic signal attenuation. The thickness of the one or more cover/intermediary pieces can be a factor in designing the specific thickness profile and/or curvature of the back piece. The orientation or positioning of a radar device with respect to the radome can also be a factor in the thickness design, or vice-versa.
Referring now to
A one-piece radome (e.g., radome 200), however, does not provide for optimal visual effects, which is desirable particularly for most vehicle applications. Specifically, the features for a one-piece radome may be limited to two-dimensional features such as a thin layer of film or paint. Therefore, a multi-piece radome is more desirable due to the more complex decorative features that can be formed. Multiple pieces, however, can create a complex problem for mitigating radar attenuation. Referring now to
The recesses and protrusions 328 and 332 can correspond to three-dimensional portions of the decorative feature (e.g., a vehicle emblem, logo, or symbol). While the recesses and protrusions 328 and 332 affect the thickness of the cover piece 304 and the back piece 316 in certain areas, a thickness T3 towards a center of the cover piece 304 can be approximately equal to a thickness T4 towards outer edges of the cover piece 304. In some implementations, the cover piece 304 can define a uniform thickness (i.e., T3=T4), but only if not accounting for the recesses 328. The back piece 316, on the other hand, can define a non-uniform thickness profile. More particularly, a thickness T5 towards a center of the back piece 316 can be less than a thickness T6 towards outer edges of the back piece 316. This non-uniform thickness of the back piece 316 mitigates radar attenuation.
One potential issue with the two-piece design of radome 300, however, is material and thickness variability across the scanning range. More particularly, when the cover piece 304 is formed of a material that has different permittivity properties than the back piece 316, the recesses and protrusions 328 and 332 can affect the radar attenuation, if not accounted for. As shown at 340, at a radar angle of approximately 0 degrees, the radar device 336 scans through a larger/thicker portion of the back piece 316 due to the recess 328. As shown at 342, on the other hand, at a radar angle of approximately 15 degrees, the radar device 336 scans through a larger/thicker portion of the cover piece 304. Similarly, as shown at 344, at a radar angle of approximately 30 degrees, the radar device 336 may scan through a side portion of the recess 328, which may be an even different thickness portion of the back piece 316 (compared to the scan denoted by 340).
To account for this potential material and thickness difference, instead of a linearly increasing curvature from center, the back piece 316 would have a non-linear changing curvature from center. An example of such a non-linear changing curvature is shown as 346 in
Instead of the two-piece radome 300, a multi-piece design having three or more pieces may be preferred. Referring now to
The sum of thicknesses T8 and T9 therefore equals thickness T7. As such, the cover piece 354 and the intermediary piece 374 collectively define a uniform thickness (T7). The back piece 366, on the other hand, can define a non-uniform thickness profile. A thickness T10 towards a center of the back piece 366 can be less than a thickness T11 towards outer edges of the back piece 366. This non-uniform thickness profile enables the back piece 366 to mitigate radar attenuation. By utilizing the same material having the same permittivity for both the cover piece 354 and the intermediary piece 374, three-dimensional features can be formed without creating a complex radar attenuation problem, such as the potential one discussed above with respect to the two-piece radome 300 of
The radome 350 can further include a decorative layer 386 disposed between the cover piece 354 and the back piece 366. Example surfaces that the decorative layer 386 can be applied to include, but are not limited to, the back surface 358 of the cover piece 354, the front surface 378 of the intermediary piece 374, the front surface 370 of the back piece 366, and combinations thereof (e.g., both the back surface 358 of the cover piece 354 and the front surface 378 of the intermediary piece 374). As previously mentioned, the shape of the intermediary piece 374, which corresponds to the recesses 362, can define a portion of a decorative feature, such as a symbol for display on the vehicle (an emblem, a logo, a decal, a nameplate, etc.). Another portion of this decorative feature is the optional decorative layer 386. Non-limiting examples of the decorative layer 386 include paint (spray, silk screen, etc.), a colored or multi-colored film (e.g., applied via hot stamping), a single or multi-colored graphic (e.g., applied via an adhesive), and combinations thereof.
Another example of the decorative layer 386 or a portion thereof is a metalloid layer. This metalloid, for example, can be applied via any suitable physical vapor deposition (PVD) technique. Non-limiting examples of PVD techniques include cathodic arc deposition, electron beam PVD, evaporative deposition, pulsed laser deposition, and sputter deposition. This metalloid, however, is not a metal. The metalloid can comprise silicon and, in some implementations, other materials (dopants, germanium, etc.). The metalloid can also be non-silicon-based. Because the metalloid can include other components (e.g., as a result of the PVD process), it can be referred to as a metalloid-based layer. In some implementations, the metalloid can include three total layers: a painted base layer, the deposited metalloid, and a top coat. Tinting, for example, could be added to either the painted base layer or the top coat in order to adjust the color of the intermediary piece 374. It will also be appreciated that the decorative layer 386 can alternatively or additionally include one or more metals. Non-limiting examples of the metal(s) include post-transition metals, such as indium and tin.
When applied to the intermediary piece 174, the metalloid may not appear metallic. Instead, the metalloid will appear as a tinting to the intermediary piece 374 (e.g., similar to window tinting). The metalloid can also define different colors. In one implementation, the deposited metalloid portion of the metalloid could be deposited such that it defines a particular thickness in order to appear vary the color and/or brightness/darkness of the metalloid. When arranged proximate/in front of the back piece 366, the metalloid may appear brighter if the back piece 366 is formed of a non-transparent resin, such as acrylonitrile styrene acrylate (ASA) and acrylonitrile butadiene styrene (ABS) plastics. It will be appreciated, however, that other non-transparent plastics could be utilized, as well as transparent plastics (e.g., which could also then be painted or otherwise masked to be translucent or non-transparent). In other words, while the metalloid may not itself appear metallic, it may appear metallic when placed in proximity to a non-transparent version of the back piece 366.
Referring now to
In some implementations, the back piece could be overmolded (i.e., over an outer edge of the front piece(s)) to secure the radome together. Alternatively, an adhesive could be utilized. The pieces could also be held together via chemical bonding (e.g., as a result of the heat generated during the molding processes). In some implementations, the back piece can further define a mounting feature configured to attach the radome to a portion (e.g., a front end) of the vehicle. Such a mounting feature, however, should not be in a viewing or scanning path of the corresponding radar device. Because the cover/intermediary pieces are complimentary and thus can be mated together, a subsequent molding step to form the radome does not require these components to be specifically aligned or held proximate to each other. This simplifies and could potentially reduce costs of the second/final molding process. At 420, the radome can then be removed from the second mold. The radome will thus include the front piece(s), the non-uniform back piece, and some sort of decorative feature (recess/protrusion, one or more decorative layers, or some combination thereof). The method 400 can then end or return to 404 to form another radome.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known procedures, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The term “and/or” includes any and all combinations of one or more of the associated listed items. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. Similarly, method or flowchart steps do not necessarily imply an order of operations (e.g., a step recited after another step could be performed before the other step, unless required as being performed after).
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
