Abstract:
A structure for retaining a sensor and a body fascia panel entails a bracket, framework, or solid material that defines a receptacle or pocket for a sensor, such as a radar sensor, and a dip or slot such that a body fascia panel may he securely held in place. Additionally, a body fascia panel may exhibit an auxiliary structure that retains the sensor, and a fastener retainer, such as a circular fastener retainer. The structure may be molded directly into the body fascia panel as may the fastener retainer. The slot to retain the body fascia panel may run along the entire length, such as at an upper area, of a bracket, framework or solid material to hold the panel. To protect a sensor, such as a radar sensor, from road debris, water and other elements, a sealant may surround the sensor.

Description:
FIELD 
       [0001]    The present invention relates to a dual purpose bracket for mounting a radar sensor and a body panel fascia. 
       BACKGROUND 
       [0002]    Modern vehicles are commonly being equipped with radar systems such that while an equipped vehicle is traveling along a road detection of surrounding vehicles is possible, particularly vehicles in a blind spot of a driver. Such vehicle detection may assist a driver of the radar-equipped vehicle with a lane change, for example. A radar sensor, as part of the radar system, may be mounted within a dedicated metal bracket under cover of a vehicle body panel. Additionally, vehicle body panels, also known as fascia, may be attached to an underlying vehicle structure using dedicated brackets specifically intended for such a mounting purpose. With single purpose or dedicated brackets, manufacturing costs, vehicle assembly costs, and the weight associated with such brackets contributes to excess manufacturing costs and vehicle weight. 
         [0003]    What is needed then is a device that does not suffer from the above disadvantages. This in turn will result in a device that permits multiple components, such as a radar sensor and a body fascia panel, to be conveniently mounted on a vehicle using a single bracket. 
       SUMMARY  
       [0004]    A structure for retaining a sensor, such as a radar sensor, and a body fascia panel may include a bracket, framework, or solid material that defines a receptacle or pocket to retain and secure the sensor. The bracket may secure a body fascia panel in a bracket slot such that an edge of the body fascia panel may reside, wedge or clip into the bracket or solid material structure. The structure to retain the sensor may be part of the body fascia panel, such as a molded portion of the body fascia panel, and additionally employ a fastener retaining portion, such as a circular fastener retaining portion for a screw or bolt. Such screw or bolt may further secure the sensor bracket and body fascia panel to the vehicle and create a robust mount. The body fascia panel may reside, fit or clip into the bracket, framework or solid structure along a longitudinal length of the bracket, framework or solid structure such as at an upper location or location proximate an edge of the structure. To protect the sensor from the elements, whether they be water, mud, dust or general road grime, the sensor is surrounded by a seal or sealant. 
         [0005]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0007]      FIG. 1  is a rear perspective view of a vehicle depicting the location of a radar sensor in accordance with the present invention; 
           [0008]      FIG. 2  is a side view of a right rear side of a vehicle depicting the location of a radar sensor in accordance with the present invention; 
           [0009]      FIG. 3  is a top view of an effective range of a radar sensor; 
           [0010]      FIG. 4  is a top view depicting a general location of a radar sensor in accordance with the present invention; 
           [0011]      FIG. 5  is an enlarged top view depicting a radar sensor in accordance with the present invention; 
           [0012]      FIG. 6  is a rear view depicting a general location of a radar sensor in accordance with the present invention; 
           [0013]      FIG. 7  is an enlarged rear view depicting a radar sensor in accordance with the present invention; 
           [0014]      FIG. 8  is a top view of a radar sensor depicting a zone within which object detection is possible; 
           [0015]      FIG. 9  is a rear view of a radar sensor depicting a zone within which object detection is possible; 
           [0016]      FIG. 10  is a left side view of a rear of a vehicle depicting a radar sensor bracket within which a radar sensor mounts; 
           [0017]      FIG. 11  is an enlarged view of a radar sensor bracket in accordance with the teachings of the present invention; 
           [0018]      FIG. 12  is a perspective view of a fascia including a bracket that secures a radar sensor; and 
           [0019]      FIG. 13  is a perspective view of a fascia including a bracket that secures a radar sensor, and a surrounding sealant. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. Turning now to  FIG. 1 , a vehicle  10 , such as an automobile, may employ a sensor  12 , such as a radar sensor, to defect objects, such as other vehicles, in the area proximate a left side and a left rear side of the vehicle  10 .  FIG. 2  depicts a location of a sensor  12  on the vehicle  10  such that objects, such as other vehicles, may be detected on a right side and a right rear side of the vehicle  10 . Continuing with  FIG. 2 , in one example, the sensor  12  is depicted in a lower area of the vehicle  10  behind a body fascia panel  14 , such as the rear bumper body fascia panel  14 . With the sensor  12  positioned or mounted in such a location on the vehicle  10 , proper sensing of surrounding objects, such as an adjacent vehicle(s), may be performed, as depicted in  FIG. 3 . 
         [0021]    Turning to  FIG. 3 , a vehicle  10  is depicted with multiple radar sensors, such as radar sensors  12 , installed on each side of the vehicle  10  as initially depicted in  FIGS. 1 and 2 .  FIG. 3  further depicts a different vehicle  16  next to and slightly behind the sensor-equipped vehicle  10 . Because the sensing vehicle  10  is equipped with at least one of the sensors  12 , the driver of the vehicle  10  may be alerted to the other vehicle  16 , which is within a close proximity to the vehicle  10  and potentially in a blind spot of the driver of the vehicle  10 . To detect the vehicle  16 , the sensor  12  of the vehicle  10  transmits, as an example, a radar signal. As depicted and described, radar sensors exhibit an advantage that they can be integrated behind a vehicle bumper  18  and thus remain unseen to an observer standing beside the rear bumper  18 , which contributes to the design aesthetics of the vehicle  10 . In contrast to the limited range of infrared technology, whose sensors may be seen resident in a vehicle bumper from the exterior of the bumper, radar sensors  12  have a range of between a few centimeters and up to 30 meters, in one example of an automotive application. Another advantage is that radar sensors are not affected by the influences of weather, unlike infrared systems. Finally, the high accuracy and resolution of radar sensors allow them to be used in applications related to safety. 
         [0022]    Continuing with  FIG. 3 , detection areas  20 ,  22  are depicted as representative areas within which a sensor  12  may be effective at detecting a vehicle  16 , which may be approaching the vehicle  10 . By detecting the vehicle  16  approaching the vehicle  10  as both are moving in the same direction along a road, the driver of the vehicle  10  will not be burdened with turning his or her head in an attempt to visually check an area that may be known as a “blind spot” to a driver of a vehicle  10 . In a multiple lane situation, such as a three lane or greater road, if the vehicle  10  is traveling along an interior lane, vehicles approaching on either side of the vehicle  10  may be simultaneously detected. 
         [0023]    Turning now to  FIGS. 4-7 , initial details of the invention will be presented.  FIG. 4  depicts the general location of the sensor  12  in vehicle  10  from a macro perspective while  FIG. 5  depicts an enlarged top view of the sensor  12  in a mounted position. Continuing with  FIG. 5 , depicted is a sensor  12  that is retained within a bracket  24  that may mount to the vehicle underbody  48 , and more specifically, the bracket  24  may be a framework or solid structure that is configured to define a pocket  26  within which the sensor  12  may reside. The bracket  24  maybe elongated, meaning the bracket may have one dimension, such as a length, that is longer than the other two, such as the thickness and width. There are a variety of ways in which the sensor  12  may fit into the bracket  24 . The sensor  12  may drop in from the top of the bracket  24  or either end of the bracket  24 , that is, in the for-aft direction of the vehicle. Continuing, the bracket  24 , framework, or solid structure may further define a slot or groove  28 , within which a projection  30  of the body fascia panel  14  may fit into to securely hold the body fascia panel  14 . The slot or groove  28  may be along the length of the bracket  24 , as opposed to the width or height. 
         [0024]    The body fascia panel  14 , also known simply as fascia  14 , may be a molded plastic or fiberglass and have at least projection  30  molded directly into a rear side of the fascia  14 . Alternatively, the projection  30  may be a separate piece and be joined to the fascia  14  by an adhesive, a heating and joining process or a fastener that passes through or into the fascia  14 . For instance, a fastener may pass from the exterior of the fascia  14 , and into the projection  30  to secure the projection to the fascia  14 . Or the projection  30  may be secured to the fascia with a fastener that passes from the inside of the fascia, first through the projection  30  and then into the fascia  14 . Regardless of how the projection is situated on the fascia  14 , the projection  30  may then be successfully pressed into the slot  28  to secure the fascia  14  to the bracket  24 . As depicted in  FIG. 5 , there may be a single projection  30  that presses into slot  28 , or a second projection  32  that presses into another slot  34 . As depicted in  FIG. 5 , the slot  28  may be viewed as the front slot, while the slot  34  may be viewed as the rear slot, keeping with the for-aft orientation of the vehicle  10 . 
         [0025]    Turning now to  FIGS. 6 and 7 , a similar arrangement as in  FIGS. 4 and 5  will be presented.  FIG. 6  depicts a vehicle  10  in which the sensor  12 , which may be the same sensor as depicted in  FIGS. 4 and 5 , is situated behind the bumper fascia  14 . Because  FIG. 7  is a view from the rear, the bracket  24  defines a top slot  36  and a bottom slot  38 , using the ground on which the vehicle is resting as a reference. Similar to the structure described in  FIG. 5 , the fascia panel  14  has a projection  40 , considered a top projection  40  for ease of reference, which fits into a top slot  36 , and a projection  42 , considered a bottom projection  42  for ease of reference, that fits into a bottom slot  38 . Similar to the prior-explained projections  30 ,  32 , the projections  40 ,  42  may be integrally molded into the fascia  14 , which may be a plastic or fiberglass material. Alternatively, the projections  40 ,  42  may be fastened to the fascia  14  using traditional fasteners, such as screws that originate from either the exterior or the interior of the fascia  14  and screw into both, the fascia  14  and either of the projections  40 ,  42 . Finally, similarly to the sensor  12  of  FIG. 5 , the sensor  12  may slide into the pocket  44  or receptacle  44  defined by the bracket  24  or framework  24 . Alternatively, the bracket  24  may instead be replaced with a solid structure, such as plastic, and have a receptacle or pocket  44  molded directly into the solid structure. Similarly, the top slot  36  and bottom slot  38  may be molded directly into such a solid plastic structure. The bracket  24  of  FIGS. 5 and 7  may mount to a vehicle underbody  48  with traditional fasteners such as screws or bolts. Additionally, if the bracket  24  is constructed as a frame-like structure, it may be made from a metal or a plastic. 
         [0026]      FIG. 8  is a top view of a representative radar sensor  12  depicting an angular range of radar detection as viewed from above the sensor  12 , while  FIG. 9  is a rear view of the representative radar sensor  12  depicting an angular range of radar defection if viewed from a front or rear of the sensor  12  or vehicle  10  within which the sensor is mounted. The radar sensor  12  depicted in  FIGS. 8 and 9  is but one example of the angular range of a radar detector that may be used in the vehicle  10  to detect surrounding vehicle(s), as depicted in  FIG. 3 . In other words, vehicles entering the blind spot area  46 , which encompasses the radar detection area of the radar sensor  12 , will be detected and alert the driver of an equipped vehicle to such detection. 
         [0027]    Turning now to  FIGS. 10 and 11 , the bracket  24  and its use in conjunction with the fascia  14  and sensor  12  will be further described.  FIG. 10  is a left side view of a rear of a vehicle. More specifically, the sensor  12  lies within a pocket or receptacle  60  formed as part of or within the frame-like or solid bracket  24 . The pocket or receptacle  60  may be rectangular or approximately rectangular, such as with rounded interior corners. The manufacturing process used to make the bracket may dictate whether sharp interior corners or rounded interior corners, for example, are manufactured into the bracket  24 . The bracket  24  may be secured to the vehicle or vehicle underbody  48  using fasteners  50 ,  52 ,  54 ,  56  while the fascia  14  fits into a slot  58  on the bracket  24 , as described in conjunction with  FIGS. 5 and 7 .  FIG. 11  depicts an enlarged view of the bracket  24  that defines a pocket within which the sensor  12  resides. Near the top edge of the bracket  24 , a slot  58  receives a projection or length of fascia edge  62  ( FIG. 10 ) to secure the fascia  14  to the bracket  24 . Thus, the bracket  24  serves the dual purpose of retaining the sensor  12  and the fascia  14 . 
         [0028]    Turning now to  FIG. 12 , the body fascia panel  14  can be seen located in front of the vehicle underbody  48 , or in other words, the underbody  48  is behind the body fascia panel  14 . More specifically, attached to as a separate piece, or molded directly into the body fascia panel  14  is an extension piece of material that functions as a sensor support  64  within which the sensor  12  resides. As depicted, the sensor support  64  may be a strand-like structure molded into the body fascia panel  14 . Alternatively the sensor support  64  may be a solid structure, as opposed to the strand-like structure, which has a material and a weight-saving advantage associated with it. Regardless of whether the sensor support  64  is molded to have strands like a framework or is molded as a solid structure, the sensor support  64  defines a sensor pocket  66  within which the sensor  12  slides into and resides for subsequent use. In addition to the sensor support  64 , a mounting support  68  lies on a side of the sensor  12  opposite to the sensor support  64 . The mounting support  68  may have a fastener area  70  through a hole  72  of which a fastener may pass. The fastener area  70  may form a complete circle to prevent a fastener from losing its grip or fastening force. Alternatively, the fastener area  70  may be semi-circular to ease in connection of the sensor support  64  and mounting support  68  to the fastener. 
         [0029]    Continuing with  FIG. 12 , the mounting support  68  may be a structure formed of strands of material as in a framework, or a solid structure, the former having greater material and weight-saving advantages than the latter. Regardless of its geometric or structural form, the sensor pocket  66  is formed in part by the mounting support  68  and the sensor support  64 . Stated another way, the sensor support  64  and the mounting support  68  bound the sensor pocket  66  and help to define the pocket  66 . The embodiment of  FIG. 12  has the advantage of incorporating a radar sensor  12  into a molded pocket  66  of a structure. The structure takes the form of a sensor support  64  and a mounting support  68  that are designed to secure the sensor  12  but also is the body fascia panel  14 . Thus, a single structure may serve multiple functions. 
         [0030]      FIG. 13  depicts the embodiment of  FIG. 12  with a seal or sealant  74  surrounding the sensor  12 . The seal or sealant  74  may be a foam, rubber or plastic material that may be installed around the sensor  12  to seal the sensor  12  to the inside surface of the fascia and protect the sensor  12  from dust, dirt, wafer and debris that the sensor  12  may be subjected to in its potential installation locations, such as in a lower fascia panel location near a road surface. 
         [0031]    There are multiple advantages of the present invention. First, the bracket  24  is capable of retaining a sensor  12  and a body fascia panel  14 , in one embodiment, the bracket  24  may be manufactured from a metal, such as steel, aluminum or magnesium. Alternatively, the bracket  24  may be manufactured from a plastic to provide advantages related to weight, rust and corrosion, and manufacturing costs. With the embodiment depicted in  FIGS. 5 and 7 , the fascia panel  14  may be installed into the bracket  24  after the bracket  24  is fastened to a vehicle underbody structure  48 .  FIG. 10  depicts such a fastening. Alternatively, the bracket  24  may be integrally molded to the fascia  14  as pad of the fascia  14  such that no separate connection between the bracket  24  and the fascia  14  is necessary to hold the bracket  24  to the fascia  14 . Such a scenario is depicted in  FIGS. 12 and 13 .  FIG. 12  depicts the advantage of having the sensor support  64  integrally molded into or as part of the fascia  14 . The embodiment depicted in  FIG. 12  may be located in a lower location of the fascia behind a rear wheel of a vehicle, as depicted in  FIGS. 1 and 2 . An additional advantage is that parts that may have previously been separate, such as a radar sensor bracket and a fascia mounting bracket, may in part be eliminated. A dual use part, such as the single piece as best depicted in  FIGS. 5 ,  7 , and  10 - 13 , eliminates multiple, separate parts. Another advantage is that by molding the radar sensor pocket  66  into the fascia sensor support  64  and fascia  14 , as depicted in at least  FIG. 12 , the sensor  12  may be properly aligned upon installation of the fascia  14  onto a vehicle  10 . That is, proper sensor alignment is molded into the fascia  14  and sensor pocket  66 , and thus, no subsequent, post-installation alignment is required. Finally, because all vehicles have body fascia panels, the present invention may be incorporated into nearly every vehicle in which radar sensors are required. 
         [0032]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.