DEVICE FOR ATTACHMENT TO AN OPENING OF A VEHICLE AND FOR COVERING AN EMITTER AND/OR A RECEIVER

Abstract

A device is provided for attachment to an opening of a vehicle and for covering an emitter and/or a receiver of electromagnetic waves (W), in particular radar waves. The device is arranged in the vehicle behind the opening, and includes a covering plate which, when attached to the opening, completely covers the opening. The covering plate is composed of a material that is at least partially transparent to electromagnetic waves. The covering plate is the only plate that covers completely the opening.

Claims

1. A device for attachment to an opening of a vehicle and for covering an emitter and/or a receiver of electromagnetic waves (W), the device arranged in the vehicle behind the opening, the device comprising: a covering plate which, when attached to the opening, completely covers the opening, wherein the covering plate is composed of a material being at least partially transparent to the electromagnetic waves, and wherein the covering plate being the only plate that covers completely the opening.

2. The device according to claim 1, further comprising a frame to which the covering plate is fixable, wherein the frame comprises one or more fasteners for fixing the device to the vehicle.

3. The device according to claim 2, wherein the frame extends substantially around the opening when the device is fixed to the vehicle body.

4. The device according to claim 2, wherein the frame has a ring-like form.

5. The device according to claim 2, wherein the covering plate and the frame are separated pieces or are integrally formed with each other.

6. The device according to claim 1, wherein the covering plate comprises one or more fasteners for fixing the device to the vehicle, the covering plate and the fasteners being integrally formed with each other.

7. The device according to claim 1, wherein the covering plate provides a homogenous layer and/or has at least a substantially consistent thickness and/or a circular circumference.

8. The device according to claim 1, wherein the covering plate is at least slightly domed.

9. The device according to claim 1, wherein the covering plate at least partially consists of a molded plastic material.

10. The device according to claim 1, wherein a front side and/or a rear side of the covering plate is at least partially covered by at least one styling layer of a cover material.

11. The device according to claim 10, wherein the at least one styling layer is manufactured such as to represent the emblem of the manufacturer of the vehicle.

12. A method of producing a device for attachment to an opening of a vehicle and for covering an emitter and/or a receiver of electromagnetic waves, the device being arranged in the vehicle behind the opening, the method comprising the steps of: providing a covering plate which, when attached to the opening, completely covers the opening and is the only plate that covers completely the opening, the covering plate being comprised of a material that is at least partially transparent to electromagnetic waves, at least partially covering at least a front and/or a rear side of the covering plate by a styling layer of a cover material, and removing material from the styling layer for producing an emblem of the manufacturer of the vehicle on the front and/or the rear side of the covering plate, or using a foil as cover material and producing the emblem in the foil.

13. The method of claim 12, wherein the covering plate is produced in a molding process.

14. The method of claim 12, wherein the styling layer is produced by metallization of the covering plate.

15. The method of claim 12, wherein the step of removing material from the styling layer for producing an emblem of the manufacturer of the vehicle on the front and/or the rear side of the covering plate further comprises one or more steps in which a laser is used for removing material from the styling layer.

16. The method of claim 12, wherein at least one lacquering step is performed on the covering plate.

17. The method of claim 12, wherein the method further comprises the step of providing a frame with one or more fasteners for fixing the device to the vehicle body, wherein, the frame is provided by a molding process.

18. The method of claim 17, wherein the covering plate is fixed to the frame (20).

19. The method of claim 12, further comprising the step of measuring an efficiency of passage of electromagnetic waves through the covering plate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Reference is now made more particularly to the drawings, which illustrate the best presently known mode of carrying out the invention and wherein similar reference characters indicate the same parts throughout the views.

[0041] FIG. 1 shows schematically in a top view an embodiment of a device which is not covered by the present invention.

[0042] FIG. 2 shows schematically in a top view an embodiment of a device according to the present invention.

[0043] FIG. 3 shows schematically the device of FIG. 2 in an exploded view.

[0044] FIG. 4 shows schematically a flow diagram of an embodiment of a method for manufacturing a device according to the invention.

[0045] FIG. 5 shows schematically a front view of the device of FIG. 2.

[0046] FIG. 6 shows schematically a rear view of the device of FIG. 2 together with a beam of electromagnetic waves.

DETAILED DESCRIPTION OF THE INVENTION

[0047] The device shown in FIG. 1 can be called a radar dome or a radome R1. The radome R1 comprises a front plate 1 and a rear plate 3 that form two superimposed layers of plates. When the radome R1 is fixed to a vehicle or vehicle body (not shown), the front and rear layers 1, 3 cover an opening behind which an emitter and/or receiver of a radar system can be placed. The radome R1 allows radar waves to pass through its front plate 1 and rear plate 3.

[0048] On a rear side of the front plate 1, a styling 5 can be applied which can be defined for example by a customer. The styling 5 can for example represent a customer's logo. Furthermore, a snap-fit system 7 on the back plate 3 can be used to fix the radome R1 to the vehicle body, for example a fascia or a grill of a vehicle.

[0049] In order to obtain a good radar performance, the thickness of the radome R1 is preferably even and constant. The geometry of the back plate 3 can compensate for thickness differences arising from the front plate 1, mainly because of the styling 5. However, between the front plate 1 and the back plate 3, one or more air gaps 9 may occur, for example because the plates 1, 3 are glued or joined together by other processes like laser welding etc. The two plates 1 and 3 as well as possible air gaps 9 may diminish the performance of the radar system.

[0050] The exemplary embodiment of a device in accordance with the present invention, as shown in FIGS. 2, 3, 5 and 6, also serves as a radome R2 and is intended for attachment to an opening of a vehicle and for covering an emitter and/or a receiver of a radar system arranged behind the opening (not shown).

[0051] The radome R2 comprises a covering plate 10 which, when attached to the opening, completely covers the opening, and the covering plate 10 is indeed the only plate that covers completely the opening. The material of the covering plate is at least partially transparent for radar waves.

[0052] The radome R2 further comprises an optional frame 20 to which the covering plate 10 can be fixed (see FIG. 3) or is fixed (see FIG. 2). The covering plate 10 has no step geometry or structure, which would disturb electromagnetic waves, in particular radar waves. Furthermore, the covering plate 10 is a single plate that covers the opening. The electromagnetic waves pass through an inner area of the covering plate 10, where no frame material is present. Thus, the radome R2 is advantageous with regard to the radiation and/or detection of radar waves. Furthermore, the frame 20 has no geometry or structure in the area where radar waves cross the device. Due to the use of a single covering plate 10 in the radome R2, the material thickness is reduced in comparison with radome R1. Furthermore, air gaps do not occur. Thus, radar performance can be effectively improved.

[0053] The frame 20 comprises one or more fasteners 30 for fixing the device to the vehicle body (not shown). These fasteners 30 serve to attach the device to the opening of the vehicle body and they can be part of a snap fit system 7 with clips 8 and/or they can provide glue areas for gluing the radome R2 to counter areas of the vehicle body. In alternative embodiments, the fasteners 30 can be arranged on the covering plate 10, so that a separate frame 20 is not required. The covering plate 10 and the frame 20 can also be joined together by known joining techniques, such as laser welding or 2 K molding.

[0054] The covering plate 10 according to the depicted embodiment is slightly domed. Thus, the covering plate 10 is convexly shaped on the side which is facing away from the opening, when the device is fixed to the vehicle body in accordance with its intended use. Hence, the covering plate 10 has the form of a curved disc and is bent towards the outside of the vehicle.

[0055] FIG. 3 shows the covering plate 10, a metallization layer 18, and a frame 20 which has a ring-like form. The frame 20 at least in substance runs around the opening when the device is fixed to the vehicle body. Then, the covering plate 10 is fixed to the frame 20, for example by gluing.

[0056] The metallization layer 18 can be a component of or can form a styling layer 11 that covers a rear side 13 of the covering plate 10. The styling layer 18 can also be a foil on which styling is applied. Thus, the foil can bear a finished design. In this case the foil is attached to the covering plate, for example by hot stamping. Alternatively, the foil can be in-molded with the covering plate, which is preferably made of a transparent material, for example polycarbonate. No laser removal or painting processes are needed. A gluing step is also not required.

[0057] As shown in FIG. 3, from the styling layer 11, material has been partially removed for producing an emblem of the manufacturer of the vehicle on the front side 13. The area of the removed material corresponds to an “A” in FIG. 3, but the contour of the area can be such as to reflect a shape of a manufacturer's emblem. Thus, a final look on the front side can be obtained. Material removal can be achieved in particular by laser de-metallization.

[0058] In a following step sprues 15 (see FIG. 5) can be cut from the covering plate 10.

[0059] As shown in FIG. 3, the frame 20 comprises four fasteners 30 for fixing the radome R2 to the vehicle body. The fasteners 30 can also be glued or can be mechanically fixed to the opening of the vehicle body. Other ways of mounting the device to the vehicle are basically also possible. The covering plate 10 can be fixed, in particular by gluing, laser welding or 2 K molding, to the frame 20.

[0060] With reference to the flow diagram of FIG. 4, in step S1 a covering plate 10 is produced in a molding process. The material of the covering plate 10 is at least partially transparent to electromagnetic waves, in particular radar waves, and optionally, it can be at least partially transparent to light waves. The covering plate 10 is molded by use of a plastic material. Other materials being at least partially transparent to electromagnetic waves are also possible.

[0061] In step S2 at least a rear side of the covering plate 10 is at least partially covered by a styling layer of a cover material, which is in particular a metal. Step S2 can include the step of providing a metallization on the rear side of the covering plate 10. Used metals are for example indium, gold, germanium, heavy metals and/or rare earths. A chrome look is preferably obtained. A covering of at least a part of the front side of the covering plate 10 is alternatively or cumulatively also possible.

[0062] In step S3 material is removed from the styling layer. Thus, an emblem (see “A” in FIG. 4) of a manufacturer of a vehicle is at least partly produced for example on the front side of the styling layer and thus visible on the front side of the covering plate 10. The removal of the styling layer material is conducted by application of a laser beam. Accordingly, a styling of the covering plate 10 can be ensured by laser de-metallization. Other methods like pad printing or usage of foils are also possible for material shaping.

[0063] In step S4, sprues 15 (see FIG. 5) are removed from the covering plate 10. In step S5, a lacquering is provided on the covering plate 10, in particular on the front side of the covering plate 10. Thus, the device can be protected against environmental influences. The lacquer can be transparent or can be colored according to the desired emblem. Illumination effects also can be considered by the application of the lacquer. In some embodiments, the step of laser removal can be repeated and thus applied two or more times. For example, for a first time to remove metallization, and for a second time to remove lacquer/paint, so that this part of covering plate is light transparent. Metallization and lacquering can be performed at least partially on the front side and/or the rear side of the covering plate 10.

[0064] As part of so-called preproduction processes P, a step S6 comprises producing a frame 20, preferably by use of a molding process. The frame 20 comprises one or more fasteners 30 for fixing the device to an opening of a vehicle body.

[0065] After the preproduction processes P, assembly processes A are executed. In step S7, the covering plate 10 is fixed to the frame 20. The fixing is conducted by gluing. Other fixing methods for example like fixing by mechanically clamping is also possible. In step S8, the efficiency of permeability for electromagnetic waves, in particular radar waves, of the covering plate 10 is measured. In step S9, the radar dome is packed for storage or transport purposes in a box 17.

[0066] The shown flow diagram is only an example. In particular, some steps can be performed in a different order. For example, the sprue cutting step could be carried out at an earlier or later stage. The process of lacquering could be carried out at an earlier or later stage, or such process could be carried out twice or even several times. The laser removal step can also be carried out several times.

[0067] FIG. 5 shows the covering plate 10 after step S5 of lacquering. As an example for an emblem, FIG. 5 depicts a removed inscription letter “A”. The removal was performed by laser de-metallization in step S3.

[0068] The thickness of the metal styling layer 11 is in a range of Accordingly, material from the styling layer 11 is removed in step S3 until a deepness also in a range of μm is obtained. The thickness of lacquer can also be in a range of As a result formed thickness changes are small such that efforts for thickness compensation for example by applying lacquer can be reduced.

[0069] FIG. 6 shows a beam of an electromagnetic wave W, in particular a radar wave, merely crossing the covering plate 10. Radar waves pass mainly through the covering plate 10. There is no substantial intersection from the frame 20, and there are no air gaps between two superimposed layers. The thickness of the covering plate 10 is constant and small. Thus, the performance of a radar system can be improved.

LIST OF REFERENCE SIGNS

[0070] 10 covering plate [0071] 20 frame [0072] 30 fastener [0073] R1 radome [0074] R2 radome [0075] W electromagnetic wave [0076] P preproduction [0077] A assembly [0078] S step [0079] 1 front plate [0080] 3 back plate [0081] 5 styling [0082] 7 snap-fit system [0083] 8 clips [0084] 9 air gap [0085] 11 styling layer [0086] 13 front side [0087] 15 sprue [0088] 17 box [0089] 18 metallization layer