High frequency antenna carrier in vehicle roof cross member

A high frequency antenna carrier in vehicle roof cross member is provided. The antenna carrier is configured to extend width-wise across a vehicle roof to provide structural support for the vehicle roof. The antenna carrier has a lower surface, and a plurality of sidewalls that meet at a common upper flange that mates in a face-to-face relationship with the vehicle roof. The sidewalls may be provided with apertures to facilitate a strong signal passage to and from the high frequency antenna through the carrier. The lower surface of the antenna carrier may be provided with apertures that are aligned with the antennas to improve signal strength.

TECHNICAL FIELD

This disclosure generally relates to a carrier for high frequency antennas. More specifically, this disclosure relates to a high frequency antenna carrier that supports a roof of a motor vehicle.

BACKGROUND

Modem vehicles may include a plethora of antennas, transmitters, receivers, and/or transceivers for various wireless technologies, such as telephone, Vehicle-to-Vehicle (V2V), Vehicle-to-Cloud or Vehicle-to-Everything (V2X), Global Navigation Satellite Systems (GNSS), Satellite Digital Audio Radio Service (SDARS), Remote Key Entry (RKE), telecommunication and Multi-Input Multi-Output (MIMO) operable over one or more frequency bands (e.g., 5G, 4G, 3G, other Long-Term Evolution (LTE) generations, WiFi, AM/FM/Digital Audio Broadcasting (DAB), and others). The antennas are typically integrated into the rear-view mirror, the front windshield, the rear windshield or window, bumpers or fascia, the dashboard, or above the roof (e.g., a shark fin antenna).

DETAILED DESCRIPTION

It should be understood that directional terms used herein are for illustrative purposes and refer to the direction relative to a vehicle in a normal, upright direction unless otherwise indicated. For example, a roof having a “lower” surface means that the surface faces toward the lower side of the vehicle.

FIG. 1shows a roof structure10of an automotive vehicle. The automotive vehicle may be a passenger vehicle such as a car, sports utility vehicle, van, crossover, pickup truck or the like. The roof structure includes a first side12and a second side14. The sides12,14can connect to and be supported by pillars. For example, a B-pillar or C-pillar may attach to the first side12at a connection point16. The roof structure may be made from stamped steel or aluminum, for example. A roof18attaches over the outside of the roof structure and defines an extreme outer surface of the vehicle, i.e., the top of the vehicle.

Roof structures typically have cross beams to support the roof.FIG. 1shows such a cross beam. For example, a cross beam20(also referred to as a roof cross member) extends across the roof structure10width-wise, from the first side12to the second side14. The roof cross member20is configured to support the roof and the structural integrity of the roof structure. The roof cross member20provides various benefits, such as helping to support the sheet metal, inhibiting caving of the roof when subjected to weight or pressure, as well as protecting the vehicle occupants in the event of a rollover accident.

As explained in the Background, modern vehicles can be equipped with a plethora of antennas. Packaging space is of importance for these antennas.

Therefore, according to various embodiments disclosed herein, an antenna carrier is provided. The antenna carrier can replace a cross beam, such as the cross beam20ofFIG. 1. The antenna carrier can house an antenna module with a plurality of the high-frequency antennas described above in a single, compact location that is flush and seamless with the vehicle roof.

FIGS. 2-4show various views of the antenna carrier connected to and supporting the roof, whileFIG. 5shows the antenna carrier in isolation. One embodiment of the antenna carrier is labeled as reference number30. The antenna carrier30has an upper flange32that is flush with and conforms to an underside of the roof18. The antenna carrier30can also attach to the sides12,14of the roof structure. Therefore, the antenna carrier30can be referred to as an antenna carrier roof support member, or the like. A headliner can extend throughout the interior of the vehicle, covering the underside of the roof and extending over the interior-facing surface of the flange32. This creates a seamless transition with the interior of the roof and the underside of the antenna carrier30.

The antenna carrier30has a plurality of sidewalls extending downward toward the interior of the vehicle. For example, referring toFIG. 5, the antenna carrier30can have a front wall36, a rear wall38that opposes the front wall36, and a pair of opposing sidewalls40,42on either lateral side of the antenna carrier30. The walls36,38,40,42extend downward from the flange32. The walls36,38,40,42all end at the flange32which is a common flange extending from these walls, and defines an upper extremity or perimeter of the antenna carrier30. A lower surface44extends between and connects lower ends of the walls36,38,40,42. The lower surface44along with the walls36,38,40,42collectively define a cavity or pocket45of the antenna carrier30.

FIG. 4shows the antenna carrier30at least partially housing an antenna module60, which is described below. And, as shown inFIGS. 2-5, the lower surface44of the antenna carrier30can have openings beneath the antenna module60for beam forming or signal tuning of the antennas in the antenna module. For example, in one embodiment the lower surface44has a plurality of openings or apertures (e.g., first aperture46, second aperture47, third aperture48) defined therein, extending entirely through the lower surface44. These openings or apertures46-48can be aligned with a respective one of the antennas in the antenna module60such that the openings are configured for beam forming and signal tuning of the antennas for optimum signal quality and strength. For proper alignment with the antennas in the antenna module, the openings46-48may be aligned such that the first opening46and the second opening47are closer together than the second opening47and the third opening48. To provide optimum signal quality and strength, the amount of surface area of the collective openings46,47,48on the lower surface44can be more than 50 percent. In other words, a surface area of the openings46,47,48can exceed a surface area of the material that makes up the lower surface44(e.g., a majority of the lower surface has a removal or lack of material). The amount of surface area of the collective openings46,47,48on the lower surface44can be more or less than 50 percent depending on design needs, with an increased surface area of the openings yielding more optimized antenna performance but less structural integrity, and vice versa. The openings or apertures46,47,48can be relatively large compared to the material of the lower surface44. Each opening46,47,48can span almost the entire width of the lower surface44(e.g., over 80 percent of the distance between walls36and38, and in some embodiments, over 90 percent of the distance). Again, more or less than 80 percent can be implemented according to different design needs, with an increased surface area of the openings yielding more optimized antenna performance but less structural integrity, and vice versa. The combined length of the openings46,47,48also exceeds the combined length of the remaining material of the lower surface44. In other words, going from side wall40to side wall42, there is more lack of material (e.g., opening) than there is material of the lower surface44.

The front wall36can also have three openings50,51,52, and the rear wall38can likewise have three openings53,54,55(as seen inFIG. 16). These openings50-55are also configured for beam forming and signal tuning of the antennas for optimum signal quality and strength. To provide optimum signal quality and strength, the amount of surface area of the collective openings50,51,52on the front wall36can be more than 50 percent. In other words, a majority of the front wall36is a lack of material created by the openings. Again, the amount of surface area of the collective openings50,51,52on the front wall36can be more or less than 50 percent depending on design needs, with an increased surface area of the openings yielding more optimized antenna performance but less structural integrity, and vice versa. This can also be true for the rear wall38. Having a majority of the front and rear walls36,38being provided with openings or lack of materials enables the signal quality and strength from the antenna to be minimally disturbed, and also creates pathways for the signals to exit and enter the antenna carrier30during wireless communication. The openings50,52,53,55may be triangular or wedge-shaped to conform to the sloping shape of the antenna carrier30, while the central openings51,54may be rectangular in shape. To improve structural rigidity while still not interfering with the signal path from the antenna within the carrier30, the side walls40,42may be entirely solid without any apertures.

A high frequency antenna module60is sized and configured to be contained within the pocket45of the antenna carrier30, between the vehicle's outer roof and the lower surface44. The module60is shown inFIG. 6, attached in the pocket45to the lower surface44. In particular, the antenna module60can mount to the regions between the apertures (described below) via a fastener such as a screw, bolt, etc.

FIG. 6shows an exploded perspective view of the high frequency antenna module60. As can be seen, the module60takes a generally flat profile to fit within the confines of the pocket45. In particular, the module60includes an outer housing or shell62with a generally planar upper surface64, and tapered or sloped opposing side surfaces65,66. When attached to the antenna carrier30, the antenna module may be spaced from (i.e., not directly touch) the walls36,38,40,42.

The antenna module60may have several antennas, transceivers, etc. located within. For example, as labeled inFIG. 6, the module60can include a MIMO 5G-sub6 antenna system including one or more of the following components: 5G Sub6 (LTE+WiFi+5G Sub6 foil antenna)61, vehicle-to-everything (V2X) antenna63, Satellite Digital Audio Radio Service (SDARS) active antenna67, and GNSS L1+L2 antenna69. Other antennas, such as those described above, can also be included. The antennas can be aligned with a corresponding one of the apertures disclosed above for signal tuning and beam forming. For example, opening46can be vertically aligned with the V2X antenna and one of the 5G Sub6 antennas, opening47can be vertically aligned with the SDARS antenna and two of the 5G Sub6 antennas, and opening48can be vertically aligned with the GNSS L1+L2 antenna and one of the 5G Sub6 antennas. The openings50-55can be horizontally aligned with the antennas. The openings remove material that might otherwise interfere or degrade the signal coming from and going to the antennas. In one embodiment, the antennas are connected to a point that is on the boundary of one of the apertures46-48.

The regions between the apertures46-48can vary in width to accommodate the shape, size, position and/or location of the antennas in the module60. In the embodiment shown inFIG. 2-5, the width of the region between apertures46and47is different than the width of the region between apertures47and48. These size differences may also be provided to account for the necessary locations of the capacitive or direct ground connections shown inFIG. 7.

FIG. 7shows the underside of the antenna module60, with antenna module ground structure70, such as metal (e.g., aluminum or steel) or conductive composite material (e.g., woven fiberglass, glass-reinforced epoxy laminate, or FR4 PCB), that provides a capacitive or direct ground connection with the underlying antenna carrier30, which can also be metal (e.g., aluminum or steel), to facilitate the capacitive connection or grounding. In an embodiment, the antenna carrier30may be a non-conductive composite material, and the antenna module ground structure70may be metal and may be considered the grounding for the antenna module60, and thus no additional grounding may be needed. In embodiments, the antenna carrier30can be connected to the surrounding roof structure which is ultimately connected to the vehicle chassis to further facilitate the capacitive connection or grounding.

FIG. 8shows one example of the location of the high frequency antenna module on a vehicle and relative to a broadcast (e.g., low frequency) location. The high frequency antenna module60may be located directly adjacent and forward of the low frequency area or module. The broadcast or low frequency module can include antennas for AM, FM, FM diversity, DAB, DAB diversity, and TV.

In another embodiment, one or more of the broadcast antennas can be included in the high-frequency antenna module60to form a singular, unitary packaged module with both high-frequency and low-frequency antennas.

FIG. 9shows an example of the location of the high frequency antenna module60, and an example of an exploded view of its implementation. In one embodiment, a cover68, such as a glass (e.g., dark or low-transparency) or non-metal composite, is placed over the antenna module as part of a seamless outer roof of the vehicle.

The antenna carrier30is designed such that a substantial portion of the carrier30can remain the same dimensions over all vehicle platforms, while a smaller portion of the carrier30can be modified to fit the desired vehicle platform. For example, as shown inFIG. 10, the central region72of the antenna carrier30, including the apertures in the lower surface and walls, can remain identical for all vehicle designs. To accommodate implementing the antenna carrier30into various vehicles, the flange regions74on either side of the carrier30can be shaped, sized and configured differently depending on the width, curvature, and shape of the vehicle to which the carrier30is being integrated. In other words, the central region72can remain the same and utilize a common design tailored for optimum antenna performance and robust scalable content integration, while the flange regions can be changed depending on vehicle platform constraints.

FIGS. 11-15show perspective views of a roof assembly with various components being removed sequentially to illustrate the interconnectivity and location of the components.FIG. 11shows a roof80defining an outer surface and boundary of the vehicle. The roof has a region82that overlies the antenna carrier30and antenna module60. That region can be glass, such as darkened, low-transparency glass, or non-metal composite.FIG. 12shows the roof80with the region82removed, exposing the underlying antenna carrier30and antenna module60.

FIG. 13shows the antenna carrier30and connected antenna module60, along with a telematic control unit (TCU)84. The antenna module60and its various antennas electrically connect to the TCU84, which processes and/or routes the data signals from the antennas to other control systems within the vehicle (e.g., autonomous control modules, communication systems, signal routers, navigation or location modules, telecommunication modules, etc.).

FIG. 14shows the antenna carrier30and the connected antenna module60with the TCU removed.FIG. 15shows the antenna carrier30with the antenna module60removed.FIGS. 16 and 17show more views of the antenna carrier30in isolation.

FIG. 18illustrates another embodiment of the antenna carrier, with similar yet modified features shown with reference numbers that increase by 100. The antenna carrier130includes apertures in the lower surface144and front wall136and rear wall138. In this embodiment, the apertures or openings146,147,148,150,151,152,153,154,155are shaped slightly different to give different signal tuning and beam forming characteristics. And, the regions between the apertures in the lower surface are identical in size in this embodiment.FIG. 19shows the antenna carrier130provided with a region182placed above, such as darkened, low-transparency glass or non-metal composite.FIG. 20shows the covered antenna carrier130attached to a vehicle roof structure180.

While the Figures illustrate the antenna carrier30in one orientation relative to the vehicle roof, it should be understood that the antenna carrier30can be inverted relative to the vehicle roof. In other words, the upper flange32may be located on a lower side of the antenna carrier30rather than the upper side. In this embodiment, the flange32can be connected to underlying structure in the roof (e.g., an inner roof panel, etc.).