Vehicular exterior door handle assembly with radar module and enhanced thermal management

A radar sensor assembly includes a sensor printed circuit board (PCB) having a first side and a second side opposite the first side. A radar transceiver is disposed at the first side of the sensor PCB and includes a plurality of antennas configured for transmitting and receiving radio frequency (RF) radiation. A heat sink is disposed adjacent to the radar transceiver and is configured to dissipate heat from the radar transceiver. The radar transceiver is sandwiched between the heat sink and the sensor PCB. The heat sink is configured to allow the RF radiation to pass therethrough without guiding the RF radiation.

FIELD OF THE INVENTION

The present disclosure relates to a vehicular radar sensor assembly and, more particularly, to a radar sensor assembly for an exterior door handle for opening a side door of a vehicle.

BACKGROUND OF THE INVENTION

A door handle for a vehicle door typically includes a handle portion that is pivotable relative to a base portion, whereby pivotal movement of the handle portion pulls at a cable or rod to electrically trigger or move a latch mechanism to release the latch and open the door. Door handles may include electronic components, such as sensors for sensing presence of an object exterior the door to, for example, operate an automatic opening function of the door or sense presence of a user exterior the door.

Radar sensors may be used for non-contact object detection in vehicles. Vehicles may include external components such as handles or side light modules that may be used to house one or more components of a radar sensor. However, such external components present several considerations, such as limited packaging space and heat dissipation constraints. Also, radar sensors and associated hardware may generate heat that must be managed to prevent overheating that can adversely impact the operation of the radar sensor and/or other devices.

SUMMARY OF THE INVENTION

A door handle assembly for a door of a vehicle configured to mount at a handle region of a vehicle door includes a handle portion mounted at the handle region of the vehicle door and having a grasping portion configured for a user to grasp when operating the door handle assembly. The handle portion includes an electronic component that, when electrically operated, generates heat at an interior portion of the handle portion. A heat dissipating element or system or device is configured to dissipate heat from the interior portion of the handle portion. The electronic component may comprise a sensor, such as a radar sensor or radar unit.

A vehicular radar sensor assembly includes a radar transceiver which includes an antenna, the antenna being configured for at least one of transmitting or receiving radio frequency (RF) radiation. The radar sensor assembly also includes a heat sink that is in thermal conductivity with the radar transceiver and configured to dissipate heat from the radar transceiver, and the heat sink is configured to allow the RF radiation to pass through the heat sink without functioning as a waveguide for the RF radiation.

The radar sensor assembly is configured to mount at a vehicle and configured to, when operated, sense objects exterior the vehicle includes a sensor printed circuit board (PCB) having a first side and a second side opposite the first side and separated from the first side by a thickness of the sensor PCB. A radar transceiver may be disposed at the first side of the sensor PCB and may include an antenna configured for at least one of transmitting or receiving RF radiation. A heat sink may be in thermal conductivity with the radar transceiver and configured to dissipate heat from the radar transceiver, the radar transceiver disposed or sandwiched between the heat sink and the sensor PCB. When the radar sensor assembly is operated, the RF radiation passes through the heat sink and the heat sink is configured to allow the RF radiation to pass through the heat sink without functioning as a waveguide for the RF radiation. For example, the heat sink may include an aperture therethrough and the antenna may be disposed at or within or aligned or juxtaposed with the aperture to transmit or receive the RF radiation through the aperture. The heat sink may include one or more ramps sloping towards the aperture.

A method of dissipating heat from a radar transceiver includes conducting heat from the radar transceiver to a heat sink in thermally-conductive communication therewith; transmitting the heat, by the heat sink, away from the radar transceiver; and passing RF radiation through the heat sink without guiding the RF radiation.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present disclosure provides a number of example embodiments of vehicle exterior components that are configured to hold one or more parts of a radar sensor, and which addresses the constraints of limited space and management of heat that is generated by operation of the radar sensor. In some embodiments, the radar sensor includes parts having a maximum operating temperature of 125 degrees C. at an ambient temperature of 80 degrees C. The present disclosure also provides example embodiments that provide water resistance to prevent the radar sensor from being adversely affected by exposure to moisture. The vehicle components may be configured to hold or house or have one or more other electronic components, such as capacitive touch sensors or light modules. Electronic components, such as radar units, often require an environment devoid of extreme temperatures to function properly. Additionally, some vehicle components such as door handles provide a surface frequently grasped and touched by users of the vehicle, who can be harmed if they contact a heated surface. For example, vehicle door handles are typically exposed to the environment (and may be exposed to direct sunlight for extended periods of time) and the operation of one or more electronic components can generate a considerable amount of added heat that is not easily dissipated from the confined interior space of the door handle.

Radar transceivers, such as the AWR 1843AOP transceiver from Texas Instruments, may include transmit and receive antennas within a shared package. Conventional cooling solutions for such radar transceivers may include a back-mounted heat sink mounted to a radar board opposite from the radar transceiver, since placing a conventional heat sink in front of the radar antennas could obstruct RF waves from being transmitted to and from the radar antennas. Due to packaging limitations, such back-mounted heat sinks may not be sufficient to provide adequate cooling for the radar board.

Referring now to the drawings and the illustrative embodiments depicted therein, an example motor vehicle12is shown to include a side door12ahaving an outer panel13with a vehicle door handle assembly10disposed thereupon (FIG.1). A side light module16also extends from a vehicle side18. The vehicle door handle assembly10is mountable to the door12aof the vehicle12and operable to release a latch mechanism (not shown) of the door12ato open the vehicle door. The door handle assembly10includes a handle portion14that is disposed at the door and that is fixedly mounted at the door or to a bracket mounted to the door. The handle portion may be movably mounted at the handle region of the vehicle door (such as pivotally mounted), whereby movement of the handle portion by a user opens the vehicle door. As discussed below, the door handle assembly10may include electronic components (such as a radar unit) disposed within the handle portion14and the electronic components may generate heat when operating. Thus, the door handle assembly10also includes a cooling or heat dissipating aspect or feature or function to cool or dissipate heat from the electronic component and/or a surface of the handle portion. As also discussed below, the radar sensor may be disposed within or at or behind one or more vehicular components or positions at or near the exterior surface of the vehicle for sensing an area or region exterior the vehicle.

FIG.1Ashows a side view of the example motor vehicle12including a tail light assembly16b, a headlight assembly16b, a rear bumper17a, a front bumper17b, a side mirror assembly20, various trim pieces21, and an applique22, such as a keypad mounted to a pillar of a door. In other words, the example motor vehicle12includes several vehicle exterior components13,14,16,16a,16b,17a,17b,20,21,22that may be used to hold one or more components of a radar sensor. Other exterior components13,14,16,16a,16b,17a,17b,20,21,22besides those listed explicitly above may also hold one or more components of the radar sensor and may incorporate one or more aspects of the designs shown in the present disclosure. For example, the exterior component may take the form of a body panel, a trim panel, and/or a roof-mounted structure, such as an antenna pod or a luggage rail.

In some embodiments, a radar sensor disposed within one or more exterior components13,14,16,16a,16b,17a,17b,20,21,22may be used for non-contact object detection (NCOD), such as, for example, to sense a user approaching and/or interacting with a closure such as the side door12aor a tailgate or lift gate of the vehicle12. In some embodiments, the radar sensor disposed within one or more exterior components13,14,16,16a,16b,17a,17b,20,21,22may be used for an advanced driver-assistance system (ADAS) such as, for example, to sense the position of other vehicles, objects, or terrain while the vehicle12is in motion.

As shown inFIG.2, the vehicle12includes a radar sensor at the handle portion14having a first field of sensing or field of view (FOV)24that extends in a rearward direction along the side18of the vehicle12, and a second field of sensing or field of view26that extends in a forward direction along the side18of the vehicle12. Similarly, a radar sensor at the side light module16has a third field of sensing or field of view28that extends in a rearward direction along the side18of the vehicle12, and a fourth field of sensing or field of view30that extends in a forward direction along the side18of the vehicle12. One or more of the fields of sensing or view may angle away from the side18of the vehicle12, at least to some extent as a result of obstruction by one or more other vehicle exterior components.

As shown inFIG.3, the handle assembly10includes a handle cover34with radar assembly having a radar transceiver36disposed therein and configured to generate and transmit radio frequency (RF) radiation38through the handle cover34. Specifically, the RF radiation38propagates through a portion of the handle cover34, which may be called a radome region40. In order to optimize transmission of the RF radiation38through the handle cover34, the radome region40may be configured to have a thickness with a predetermined first distance d1or an integer (n) multiple of the predetermined first distance d1. The predetermined first distance d1may be determined to maximize radar transmission through the radome region40. Likewise, the radar transceiver36may be spaced apart from the radome region40by a predetermined second distance d2or an integer (n) multiple of the predetermined second distance d2to optimize transmission of the RF radiation38through the handle cover34. While radar assembly is shown as embodied in the door handle assembly, radar assembly may be provided within other types of housings, such as appliques, as a standalone radar module, integrated within a headlight or taillight assembly, within an inside mirror, or other confined spaces. In a possible configuration, the front-mounted heat sink60described herein below may act as part of the housing.

As shown inFIG.3A, the handle assembly10includes a radar module32disposed within the handle cover34. The radar module32includes a sensor printed circuit board (PCB)33with several electric components, including a radar transceiver36, mounted thereto. The sensor PCB33may provide power to the radar transceiver36. The sensor PCB33may perform other tasks, such as signal processing, and communication of information between the radar transceiver and external devices. The radome region40includes flat surfaces41extending parallel to the radar transceiver36and parallel to one another and spaced apart from one another by the predetermined first distance d1. The radome region40is spaced apart from the radar transceiver36by an air gap having the predetermined second distance d2.

As shown inFIG.3B, the handle assembly10includes the radar module32disposed within the handle cover34, mounted near a front of the handle portion14, with the radar transceiver36angled slightly forwards and downwards. As shown inFIG.4, the radome region40may be thinner than other regions of the handle cover34outside of the radome region40.

As shown inFIG.5, the vehicle exterior component13,14,16,17includes a class-A surface42that is intended to be directly viewed and/or touched by a user. In other words, the radome40includes the class-A surface42, so there is no air gap between the radome40and the class-A surface42. A housing44is sealed against an interior surface46opposite the class-A surface42. The housing44defines an interior space48configured to hold the radar transceiver36. The housing44may be configured to be watertight to prevent moisture from affecting the radar transceiver36.

As shown inFIG.6, the radar transceiver36includes a substrate50having a square shape with a flat front surface52. For example the substrate50may have length and width dimensions of 15 mm by 15 mm. The substrate50may be a printed circuit board (PCB), semiconductor or semiconductor package material, such as plastic or ceramic. The substrate50may comprise any suitable size and/or shape, and the substrate50may be made of a different material. The radar transceiver36may include, for example, an AWR 1843AOP device from Texas Instruments.

The radar transceiver36includes a set of four radar transmitting antennas54, which may be called TX antennas, and which are configured to transmit radio frequency (RF) radiation, and particularly RF radiation at radar frequencies, such as 76- to 81-GHz. Each of the radar transmitting antennas54is disposed on or flush with the flat front surface52of the substrate50. The radar transmitting antennas54each have a rectangular shape and are disposed along a first axis A, which extends parallel to an edge of the substrate50. The rectangular shape of each of the radar transmitting antennas54defines a major axis (i.e. the longer one of a length or width thereof) that is tilted at an oblique angle, such as 45 degrees, with respect to the first axis A. The radar transceiver36includes a set of three radar receiving antennas56, which may be called RX antennas, and which are configured to receive radio frequency (RF) radiation, and particularly RF radiation at radar frequencies, such as 76- to 81-GHz. Each of the radar receiving antennas56is disposed on or flush with the flat front surface52of the substrate50. The radar receiving antennas56each have a rectangular shape and are disposed along a second axis B, which extends perpendicularly to the first axis A. One of the radar receiving antennas56is located at the intersection of the first axis A and the second axis B. The rectangular shape of each of the radar receiving antennas56defines a major axis that is parallel to the major axes of the of each of the radar transmitting antennas54, and which is tilted at an oblique angle, such as 45 degrees, with respect to the second axis B. It should be appreciated that these are merely examples, and the radar transceiver36may have any suitable number of radar transmitting antennas54and any suitable number of radar receiving antennas56, which may have any suitable configuration and/or orientation than is shown inFIG.6. Furthermore, one or more radar antennas54,56may function as both a radar transmitting antenna54, and as a radar receiving antennas56.

The radar transceiver36may include other components mounted on and/or or within the substrate50. Such other components may include electronic components, such as amplifiers and/or signal processors for generating and/or processing signals to and from the radar antennas54,56. The radar antennas54,56and/or the other components may generate heat during their operation. Such heat may need to be dissipated away from the radar transceiver36in order to keep the radar transceiver36within an operational temperature range.

FIGS.7A-7Dshow a front-mounted heat sink60configured to be mounted to the flat front surface52of the radar transceiver36. The front-mounted heat sink60may be made from one or more pieces of metal, such as Aluminum or Copper, for conducting heat away from the radar transceiver36. The front-mounted heat sink60may be configured to pass the RF radiation through the heat sink without guiding the RF radiation. In other words, the front-mounted heat sink60may include geometry and/or materials that do not reflect or otherwise guide or direct the RF radiation to or from the radar antennas54,56.

As shown inFIG.7A, the front-mounted heat sink60may have a generally rectangular shape including a front side62that is configured to face outwardly and away from the radar transceiver36when the front-mounted heat sink60is mounted to the radar transceiver36. As shown inFIGS.7B and7D, the front mounted heat sink60includes a rear side72opposite of the front side62. The front-mounted heat sink60may include a set of first apertures64each having a shape, size, and position to overlie corresponding ones of the radar transmitting antennas54for RF radiation to pass through unimpeded. The front-mounted heat sink60may further include a set of second apertures66having a shape, size, and position to overlie corresponding ones of the radar receiving antennas56for RF radiation to pass through unimpeded. The front-mounted heat sink60may also include a set of third apertures68each having a shape, size, and position to overlie corresponding components of the radar module32, such as a tall electrical component mounted to the sensor PCB33and/or a port or plug or other component that requires access for use or maintenance. The apertures extend from the front side62to the rear side72and any or all of the apertures64,66,68may have a quantity, size, shape, and/or position that is different from the example arrangement shown inFIGS.7A-7D.

As shown inFIGS.7A and7C, the front side62of the front-mounted heat sink60may define a set of first ramps70aand a set of second ramps70bthat each slope toward corresponding ones of the first apertures64. One of the first ramps70aand a corresponding one of the second ramps70btogether define a V-shaped groove that slopes downwardly toward a corresponding one of the first apertures64, where the front-mounted heat sink60may have a small or thin or slim or reduced thickness. The front side62of the front-mounted heat sink60may also define a set of third ramps70cand a set of fourth ramps70dthat each slope toward corresponding ones of the first apertures64, from a side opposite from the first and second ramps70a,70b. One of the third ramps70cand a corresponding one of the fourth ramps70dtogether define a V-shaped groove that slopes downwardly toward a corresponding one of the first apertures64, where the front-mounted heat sink60may have a small or thin or slim or reduced thickness. The V-shaped grooves defined by each of the first and second ramps70a,70b, and the third and fourth ramps70c,70dmay each extend parallel to a major axis of the front-mounted heat sink60. Together, the first ramps70a, second ramps70b, third ramps70c, and fourth ramps70dprovide clearance for RF radiation to be transmitted from the transmitting antennas54, unimpeded. In other words, the ramps70a-70dallow the RF radiation to pass through the front-mounted heat sink60without guiding the RF radiation. The front side62of the front-mounted heat sink60may define a set of fifth ramps70eand a set of sixth ramps70fthat each slope toward corresponding ones of the second apertures66. One of the fifth ramps70eand a corresponding one of the sixth ramps70ftogether define a V-shaped groove that slopes downwardly toward a corresponding one of the second apertures66, where the front-mounted heat sink60may have a small or thin or slim or reduced thickness. The front side62of the front-mounted heat sink60may define a set of seventh ramps70gand a set of eighth ramps70hthat each slope toward corresponding ones of the second apertures66, from a side opposite from the fifth and sixth ramps70e,70f. One of the seventh ramps70gand a corresponding one of the eighth ramps70htogether define a V-shaped groove that slopes downwardly toward a corresponding one of the second apertures66, where the front-mounted heat sink60may have a small or thin or slim or reduced thickness. The V-shaped grooves defined by each of the fifth and sixth ramps70e,70f, and the seventh and eighth ramps70g,70heach extend perpendicular to the major axis of the front-mounted heat sink60. Together, the fifth ramps70e, sixth ramps70f, seventh ramps70g, and eighth ramps70hprovide clearance for RF radiation to be transmitted to the receiving antennas56, unimpeded. In other words, the ramps70e-70hallow the RF radiation to pass through the front-mounted heat sink60without guiding the RF radiation.

A slot71for receiving a clamp, such as a spring clamp, for holding the front-mounted heat sink60in contact with the radar transceiver36may be disposed along each long-side edge of the front mounted heat sink60. The rear side72may include a flat plate74having a size and shape configured to be flush against the flat front surface52of the substrate50of the radar transceiver36for conducting heat away from the radar transceiver36. The front-mounted heat sink60may include side walls76configured to engage side edges of the substrate50of the radar transceiver36for holding the substrate50in a precise alignment with the front-mounted heat sink60. The front-mounted heat sink60may include integrated clips78for holding corresponding side edges of the substrate50of the radar transceiver36. The integrated clips78may provide a biasing force to press the substrate50against the flat plate74of the front-mounted heat sink60to maintain good thermal conductivity therebetween.

The rear side72of the front-mounted heat sink60may define a plurality of raised regions80configured to accommodate corresponding electrical devices mounted to the sensor PCB33. The rear side72of the front-mounted heat sink60may include stand-offs that each define a flat surface that are parallel to one another and which are farthest from the front side62. The standoffs82may be configured to engage the sensor PCB33and to distribute pressing force to the sensor PCB33, preventing excessive force from being applied to the radar transceiver36.

As shown inFIGS.8and9, the radar sensor includes the front-mounted heat sink60, including the first and second apertures64,66for transmitting RF radiation therethrough, and the third apertures68for accommodating components on the sensor PCB33. One or more of the third apertures68may provide access to a corresponding location on the sensor PCB33, for accessing a test port, a status indicator, a wiring connection, or for any another purpose.

As shown inFIG.10A, transmitted RF radiation90from the radar transmitting antennas54passes unimpeded through the first apertures64of the front-mounted heat sink60, without being guided or otherwise disturbed by the front-mounted heat sink60. As illustrated, received RF radiation92passes unimpeded through the second apertures66of the front-mounted heat sink60to one of the radar receiving antennas56, without being guided or otherwise disturbed by the front-mounted heat sink60.

FIG.10Billustrates the electromagnetic waves90in a diagrammatically simplified form as a conical shape emitted from transmitting antennas54and expanding outwardly and electromagnetic waves92in a diagrammatically simplified form as a conical shape being received by radar receiving antennas56, where the aperture64,66is aligned with the antenna54,56and is configured as narrow as possible so as not to affect the field of the conically shaped emitted electromagnetic wave90. In other words, the aperture is configured, and the height of the aperture64is configured so that terminal ends64aof the aperture do not affect the propagation of the waves90outwardly, for example by being positioned so as to cause a reflection of the waves90when contacting the terminal ends64a. As a result, a heat sink structure may be provided which does not block the field of sensing or view of the antennas54,56over a conically shaped propagation volume, for example, prior to the waves90exiting the aperture64. Similarly, the field of sensing or view of the receiving antenna56is optimized for a maximized field of sensing or view by configuration terminal ends64bof aperture66. For example, the height of the aperture64,66may be calculated so as not to act as a waveguide according to the below formula and with reference toFIG.10Csuch that the frequency of the waves90,92are not cut off due to the dimensions of the aperture64,66:

Fc is the cut-off frequency, C is the speed of light, μ is the permeability of a material within or covering the heat sink60(or otherwise within the field of sensing or view of the antennas), for example the material may comprise air or foam inserted in apertures64,66, and ε may be the permittivity of another material within or covering the heat sink60, for example air or foam inserted in apertures64,66. In some configurations, waves90,92may slightly impinge on terminal ends64a,64b.

As shown inFIG.11, the radar transceiver32with the front-mounted heat sink60is mounted within an enclosure94(e.g., within a door handle assembly) and includes a filler96of radar-transparent material, such as potting material, disposed within each of the first and second apertures64,66. The filler96may prevent moisture, such as condensation, or other contaminants, such as dust or dirt from forming or accumulating between the antennas54,56and the enclosure94.

As shown inFIG.12, the radar transceiver32may include a back-mounted heat sink100disposed adjacent to a back side102of the sensor PCB33, opposite from the radar transceiver36. The back-mounted heat sink100may make contact with a back side102of the sensor PCB33for transmitting or dissipating heat therefrom. Alternatively, the back-mounted heat sink100may be spaced apart from the back side102of the sensor PCB33, thus precluding the back-mounted heat sink100from short circuiting any components of the sensor PCB33. In some embodiments, the front-mounted heat sink60and the back-mounted heat sink100may be two pieces or parts or portions of a sensor heat sink, which may be formed from a single, or monolithic, piece of material. In some embodiments, the sensor heat sink may include two or more pieces or parts or portions, including the front-mounted heat sink60and the back-mounted heat sink100, which may be joined together to form a heat sink assembly.

In some embodiments, the radar transceiver32includes a post104that extends through a hole106in the sensor PCB33. The post104provides thermal conductivity between a back side53of the radar transceiver36and the back-mounted heat sink100. Such a configuration may help to remove heat generated by power electronic devices, such as transistors, located within the radar transceiver36and adjacent to the back side53thereof. A compliant thermal conductor110, such as thermally-conductive paste, may be disposed between the back side53of the radar transceiver36and the post104to enhance thermal conduction therebetween.

In some embodiments, the back-mounted heat sink100includes a lip108adjacent to the post104, which is configured to engage the back side102of the sensor PCB33, thereby preventing the post104from imparting an excessive force on the back side53of the radar transceiver36, which could otherwise damage the radar transceiver36.

As shown inFIG.13, a method1000of dissipating heat from a radar transceiver36includes, at step1002, conducting heat from the radar transceiver36to a heat sink in thermally-conductive communication therewith. For example, the front-mounted heat sink60may conduct heat from the radar transceiver36. At step1004, the method1000includes transmitting the heat, by the heat sink, away from the radar transceiver. For example, the front-mounted heat sink60may transmit the heat away from the radar transceiver36. At step1006, the method1000includes passing RF radiation through the heat sink without guiding the RF radiation. For example, the first apertures64and the second apertures66of the front-mounted heat sink60may allow the unimpeded passing of the RF radiation through the front-mounted heat sink60to or from a corresponding antenna54,56of the radar transceiver36.

Thus, a radar sensor disposed at a vehicle transmits RF radiation exterior the vehicle and receives reflected RF radiation such as for object detection. The radar sensor may be disposed at any suitable vehicle component, such as within a door handle assembly of the vehicle. The radar sensor generates heat that must be dissipated to maintain a suitable operating temperature for the radar sensor. A front-mounted heat sink may be mounted or attached or otherwise disposed at a front surface of the radar sensor for dissipating heat from the radar sensor. To reduce or eliminate or preclude interference or guidance of the RF radiation by the front-mounted heat sink, the front-mounted heat sink is configured to allow RF radiation to pass through without interfering or guiding the RF radiation. For example, the front-mounted heat sink may include one or more apertures that align with one or more corresponding antennas of the radar sensor. The front-mounted heat sink may also include a series of ramps configured to define V-shaped grooves. The V-shaped grooves may align with or frame or correspond to the one or more apertures to allow RF radiation to emanate unimpeded from antennas aligned with the apertures.

When a radar sensor, or any suitable heat-generating electronic component, is disposed at a door handle assembly of a vehicle, dissipating heat from the electronic component and the door handle assembly is important for maintaining a suitable operating temperature for the electronic component and to avoid presenting a heated surface that a user may grasp when opening and closing the vehicular door. As discussed below, a vehicular door handle assembly that includes a heat-generating electronic component may include a front-mounted heat sink, such as described above, and/or one or more other heat dissipating components or features.

As shown inFIG.14, the vehicular door handle assembly210includes a handle portion214and the handle portion includes one or more electronic components, such as a printed circuit board (PCB) and/or the radar unit. For example, the door handle may include the radar sensor or sensing unit for sensing proximity of objects as part of an automatic liftgate or door locking/unlocking or closing/opening function of the vehicle. The handle may include additional or other electronic components within the door handle The door handle includes one or more electronic (and heat generating) components disposed within the handle portion and one or more heat dissipating or cooling components configured to provide thermal management at the door handle such as by reducing the temperature within the handle portion and/or dissipating heat from the electronic component, thus providing thermal management solutions at a door handle system level for integration of a mmWave radar module used to detect objects for applications such as power-door actuation or the like.

In reference toFIGS.14-17, the door handle assembly210includes a handle portion214that includes a pivot end216pivotally attached at the door and a latch end218connected to a latch mechanism to operate a latch when a user grabs and/or pulls the handle to open the door. As shown inFIG.16, a radar unit220is disposed within the handle portion214of the door handle assembly. The radar unit220includes a printed circuit board (PCB) that includes electronic circuitry or components (including electronic circuitry, including transmitting antennas and receiving antennas and optionally a processor for controlling the antennas and/or for processing outputs of the receiving antennas). The PCB may comprise a rigid PCB or may comprise a flexible PCB that may conform to the curvature or form of the handle portion.

The radar unit is disposed within a hot zone214aof the interior of the door handle assembly where heat generated by operation of the radar unit is at least partially retained and thermally separated from a cold zone214bof the interior of the handle portion by a thermally insulating barrier222. The thermally insulating barrier222separates the interior portion of the handle portion of the door handle assembly into the hot zone214a(where the radar unit operates and generates heat) and the cold zone214b(where there is not an electronic component generating heat) so that heat generated by operation of the radar unit may be dissipated from the hot zone to the cold zone and then more readily dissipated from the handle portion at the cold zone. A heat pipe224thermally connecting the radar unit220to the cold zone protrudes from the radar unit, through an aperture in the thermally insulating barrier, and into the cold zone.

The heat pipe224may comprise a solid bar of thermally conductive material (such as aluminum or copper) or may include a working fluid configured to carry heat away from the radar unit and thus from the hot zone to the cold zone. The heat pipe224may terminate in the handle portion (such as within the cold zone, such as shown inFIG.16) or the heat pipe may terminate exterior the handle portion or within the door cavity. As shown inFIG.17, the heat pipe may be in thermally conductive connection with the PCB of the radar unit, such as via a thermal grease226, to provide enhanced heat dissipation from the radar unit. Optionally, the heat pipe may be in thermally conductive connection with a heat sink element disposed at the radar unit, such as a front-mounted heat sink element as described above, to further draw heat from the radar unit within the hot zone to the cold zone and/or exterior of the handle portion. Optionally, the handle portion may include air vents or vent slots230disposed at or formed through an exterior wall or portion of the handle portion to allow airflow from exterior the door handle and to promote convection and heat dissipation of heat emanating from the heat pipe in the cold zone.

The heat pipe may terminate in the handle portion (such as within the cold zone, such as shown inFIG.16) or the heat pipe may terminate exterior the handle portion or within the door cavity. For example, and with reference toFIGS.18and19, the door handle assembly may include a device designed to exhaust thermal energy outside of the handle assembly. For example, a door handle assembly310may include a heat pipe324that extends from the radar unit320and that passes through the thermally insulating barrier322and is connected to or received within a heat sink element328. The heat sink element328receives the heat pipe324within the cold zone in the interior of the handle portion and protrudes outside of the handle body to move thermal energy outside of the handle portion. For example, an end325of the heat pipe or heat sink may protrude from the handle body at the pivot end316of the handle portion314to be disposed within and dissipate heat from the radar unit to the cavity of the door of the vehicle.

Referring toFIGS.20-22, a door handle assembly410may include a handle portion414, and the handle portion may be configured to provide active cooling for the electronics during driving or operation of the vehicle, such as by including air inlets to promote airflow through and around the handle portion. During vehicle operation, airflow is channeled through the body of the handle to cool the electronics. The handle portion414may include active air inlets430so that airflow enters from the front of the handle (at the pivot end416), where the front of the handle is towards the front of the vehicle so that as the vehicle travels forward, airflow travels along the handle from the front to the rear of the handle and across the electronics to promote heat dissipation. The handle portion may include channels432such as to direct airflow in and around the radar unit420and/or one or more heat sinks420aattached to or integrated into the radar unit to promote additional heat dissipation. The heat sinks420aattached to or integrated into the radar unit420may be disposed at the PCB of the radar unit (that includes electronic circuitry, including transmitting antennas and receiving antennas and optionally a processor for controlling the antennas and/or for processing outputs of the receiving antennas) and connected to the radar unit, such as at a cutout at the rear of the radar unit (with the PCB at the cutout may be formed to receive a portion of the heat sink to connect to the heat sink). The channels432may be disposed at the interior surface of the handle portion. One or more active air outlets434may be disposed at the rear of the handle portion to direct airflow out of the handle portion. The one or more active air inlets and/or active air outlets may be designed into and disposed at any location on the handle assembly to promote active airflow through the handle when the vehicle is in operation.

Optionally, and such as shown inFIGS.23and24, a door handle assembly510may provide active cooling of the electronic components via a fan assembly536disposed at the front of the interior portion of the handle portion514(at the pivot end516). The fan assembly536directs air, such as from a fan air inlet530, toward the radar unit520(and over and around a heat sink element520aconnected to the PCB of the radar unit via a cutout) within the interior of the handle portion to provide the active cooling and maintain a suitable temperature at the radar unit, such as under 115 degrees Celsius, in all conditions. The air may vent through fan air outlets534to promote convection. Optionally, the fan assembly may be disposed at the rear of the interior portion of the handle portion near the fan air outlets to increase exhaust of hot air from the handle portion. The fan assembly536may comprise any suitable fan assembly, such as one that uses 0.15 Watts of power and provides 0.17 cubic feet per minute (CFM) of airflow and may be electrically powered via a power source of the vehicle. For example, the fan assembly536may be electrically connected to the same power source as the radar unit520within the handle assembly.

It should be understood that the arrows depicting airflows through the handle (such as inFIGS.20-24) merely show possible airflows from the air inlet, through the handle portion (such as directed by channels and/or a fan assembly), to the air outlets. Other configurations of the door handle assembly are possible with various locations and arrangements of air inlets, air outlets, and/or channels for providing heat dissipation from the handle portion. For example,FIG.25depicts a door handle assembly610where active air inlets630, air channels632and active air outlets634are disposed in the handle portion to allow and guide active airflow while the vehicle is in motion. Additionally, passive air inlets631and passive air outlets635allow passive airflow when the vehicle is not in motion. The handle portion is designed to encourage natural convection and promote airflow over the radar unit620(and integrated or connected heat sink620a) of the door handle assembly.

The electronic components may also be in thermally conductive connection with other heat dissipating devices. For example, and as shown inFIG.26, a door handle assembly710includes a metallic wire sheath assembly738in thermally conductive connection with the radar unit720. The wire sheath assembly738may comprise a wire bundle738awrapped in a metallic sheath738bor braid or potting material. The sheath assembly is run through the handle portion to be connected to the radar unit720(such as at the heat sink720a) and is in thermally conductive connection exterior the handle assembly to draw thermal energy out of the housing. For example, the sheath assembly738may be attached to a heat sink exterior the handle assembly and/or disposed in the cavity of the door of the vehicle.

If the handle assembly comprises a fixed handle (where the handle is not pivotable relative to the door of the vehicle), such as shown inFIGS.27-29, the door handle assembly may comprise a handle portion fixedly mounted at a door of a vehicle via metallic studs (whereby the door is opened via a sensor that senses touch or proximity of a user's hand at the handle portion). For example, and as shown inFIGS.27and28, a fixed door handle assembly810includes a radar unit820disposed within the handle portion814and in thermally conductive connection with the metallic studs840mounted to the door of the vehicle. Thus, heat generated by the radar unit820may be dissipated through the studs840and/or out to another heat dissipating component (such as the door of the vehicle or a heat sink or other component disposed at the door or handle bracket of the vehicle).

As shown inFIG.28, the radar unit820may be in thermally conductive connection with a metallic diecast core842of the handle portion that is in turn in thermally conductive connection with the studs840. The metal die cast (of the metallic core) makes contact with the radar module820(such as at a heat sink of the radar module) via direct contact (metal to metal) or via indirect contact. For example, the radar unit may be in thermally conductive connection with the metallic core842through a thermally conductive paste, gel, or pad disposed between the radar unit and the metallic core of the handle assembly. The metallic core842may be overmolded with a plastic cover844to provide the class-A portion of the handle that is touched when a user grabs the handle. The plastic cover844provides a less thermally conductive surface to touch, thereby mitigating the chance that a user could burn their fingers due to heat generated from the radar unit when the user is grabbing the door handle.

With reference toFIG.29, a fixed door handle assembly910includes an entirely plastic handle portion914(as a singular piece or with separate non-metallic core and cover) and a radar unit920in thermally conductive contact with the studs940. In the illustrated embodiment, the stud makes contact with a heat sink of the radar unit. The studs may have a larger slug of material comprising a mounting component946to help pull heat from the unit to the heat sink. For example, the radar unit920may be in thermally conductive connection with one or more of the metallic studs through mounting at a mounting plate or bracket and/or via a thermally conductive paste, gel, or pad disposed between the radar unit and the metallic stud or mounting portion. Alternatively a heat sink or metal component that is not the stud could pass from the handle portion through the door to make contact with a larger heat sink in the door or handle bracket.

Thus, the door handle assembly is disposed at a door of a vehicle and includes electronic components (such as a radar unit) that generate heat. The handle assembly includes one or more heat dissipating or cooling features for regulating the temperature of the electronic components. The above described heat dissipating features may be implemented individually or combined with one another to provide the desired or appropriate cooling features, depending on the particular door handle application.

The door handle assembly may comprise any suitable type of door handle assembly, and may include or incorporate aspects of the door handle assemblies described in U.S. Pat. Nos. 6,349,450; 6,550,103; 6,907,643; 7,407,203; 8,333,492; 8,786,401; 8,801,245 and/or 9,290,970, and/or U.S. Publication Nos. US-2020-0130646; US-2020-0122631; US-2019-0106051; US-2010-0088855 and/or US-2010-0007463 and/or U.S. patent application Ser. No. 17/305,826, filed Jul. 15, 2021, and/or U.S. provisional application Ser. No. 63/200,339, filed Mar. 2, 2021, which are hereby incorporated herein by reference in their entireties. Although shown as a strap type handle, the handle assembly may comprise any suitable type of vehicle door handle assembly, such as a paddle type vehicle door handle assembly (having a paddle or the like that may be pulled at to open the vehicle door) or other type of vehicle door handle assembly. Optionally, aspects of the handle assembly may be suitable for use with a liftgate handle assembly for a liftgate or tailgate of a vehicle.

Optionally, the door handle assembly may comprise a flush door handle assembly such as of the types described in U.S. Pat. No. 8,786,401 and/or U.S. Publication No. US-2020-0102773, which are hereby incorporated herein by reference in their entireties. Optionally, the door handle assembly may include a soft touch handle portion, such as utilizing the principles described in U.S. Pat. Nos. 6,349,450; 6,550,103 and/or 6,907,643, which are hereby incorporated herein by reference in their entireties.

The radar sensors disposed in the door handle portion may comprise a plurality of transmitters that transmit radio signals via a plurality of antennas, a plurality of receivers that receive radio signals via the plurality of antennas, with the received radio signals being transmitted radio signals that are reflected from an object present in the field of sensing of the respective radar sensor. The radar sensors may be part of a system that may include an ECU or control that includes a data processor for processing sensor data captured by the radar sensors.

Optionally, the electronic components within the door handle assembly may include sensing techniques to detect presence of the user's hand near the door handle assembly or in the pocket region of the door handle assembly. For example, the door handle assembly may provide capacitive sensing, SURETOUCH™ sensing, pressure (i.e., piezoelectric) sensing, inductive sensing, or the like, and/or may provide for mechanical actuation of the door latch mechanism by the user's hand in the pocket region.

Optionally, the door handle assembly may include or may be associated with an antenna for receiving signals from or communicating with a remote device. For example, the antenna (such as, for example, an antenna of the types described in U.S. Pat. Nos. 9,484,626 and/or 6,977,619, which are hereby incorporated herein by reference in their entireties) may communicate a signal to a door locking system via a wire connection or the like, or wirelessly, such as via a radio frequency signal or via an infrared signal or via other wireless signaling means. Such connections can include cables, wires, fiber optic cables or the like. The communication to the locking system may be via a vehicle bus or multiplex system, such as a LIN (Local Interconnect Network) or CAN (Car or Controlled Area Network) system, such as described in U.S. Pat. Nos. 6,291,905; 6,396,408 and/or 6,477,464, which are all hereby incorporated herein by reference in their entireties. The vehicle door may then be unlocked and/or an illumination source or sources may be activated as a person carrying a remote signaling device approaches the door handle. Optionally, other systems may be activated in response to the remote signaling device, such as vehicle lighting systems, such as interior lights, security lights or the like (such as security lights of the types disclosed in U.S. Pat. Nos. 8,764,256; 6,280,069; 6,276,821; 6,176,602; 6,152,590; 6,149,287; 6,139,172; 6,086,229; 5,938,321; 5,671,996; 5,497,305; 6,416,208 and/or 6,568,839, and/or U.S. Publication No. US-2013-0242586, all of which are hereby incorporated herein by reference in their entireties), or the vehicle ignition, or any other desired system. The door handle and/or illumination module may be in communication with other systems and/or controls of the vehicle door and/or vehicle, such as by utilizing aspects of the door systems described in U.S. Publication No. US-2010-0007463, which is hereby incorporated herein by reference in its entirety.