Sensor cover

This patent application relates to Design application Ser. No. 29574795, 29574798, 29574799 and 29574821 all which were filed on Aug. 18, 2016, all of which are hereby incorporated by reference in their entireties.

This disclosure relates to sensors and sensor covers.

Existing vehicles, such as sedans or trailers, include autonomous driving technologies (e.g., automatic parking programs or automatic steering programs) that depend on accurate sensor measurements. To produce reliable measurements, sensors should be protected from damaged via sensor covers.

An assembly includes (a) a sensor comprising a bolt connector, an anti-rotator configured to snap-fit into a recess, and rails; (b) a cover comprising a plurality of slots configured to receive the rails and being sized to leave a portion of the bolt connector laterally exposed when finally positioned over the sensor.

According to various embodiments, at least one of the slots is a snap slot.

According to various embodiments, the snap slot includes a tongue and lip configured to snap fit over an end of one of the rails.

According to various embodiments, at least two of the slots are snap slots.

According to various embodiments, the snap slots are located on opposing sides of the cover.

According to various embodiments, the tongues of the snap slots have different lengths.

According to various embodiments, the bolt connector defines a bolt hole and a nut sits in the bolt hole.

According to various embodiments, the nut is longer than the bolt hole such that top and bottom surfaces of the nut protrude from the bolt hole.

According to various embodiments, the rails include a first rail, a second rail, and a third rail.

According to various embodiments, the first rail is shorter than the second and third rails.

According to various embodiments, the first rail protrudes from the bolt connector.

According to various embodiments, the snap slot with the longer tongue engages the first rail.

According to various embodiments, the first rail protrudes from the sensor in a first direction, the second rail protrudes from the sensor in a second direction, and the third rail protrudes from the sensor in a third direction.

According to various embodiments, the first direction is parallel with the second direction and both of the first and second directions are perpendicular to the third direction.

According to various embodiments, the sensor comprises a power supplier with a plurality of power supply rails.

According to various embodiments, the power supplier terminates at a first end and at least two of the plurality of power supply rails are flush with the first end.

According to various embodiments, the cover is sized to expose at least a portion of each of the plurality of power supply rails, such that when the cover is finally positioned over the sensor, the exposed rails are externally visible.

According to various embodiments, the cover includes an attachment ribbon.

According to various embodiments, the attachment ribbon includes a flexible extension and a cylindrical hoop.

An assembly for a vehicle includes a top housing rotatable about a bottom housing via a hinge; a sensor positioned between the top and bottom housings; the top and bottom housings each comprising a triangular portion that narrows into a rectangular extension portion; the bottom housing comprising raised bosses defining bolt apertures; the housings comprising outward indentations and corresponding inward indentations.

According to various embodiments, the top housing is rotatable about the bottom housing to an open position and a closed position.

According to various embodiments, in the closed position, the outward indentations sit on the inward indentations.

According to various embodiments, in the closed position, the indentations cooperate to retain the top housing in the closed position.

According to various embodiments, the inward indentations are symmetrical and the outward indentations are symmetrical.

According to various embodiments, the top housing comprises a hood outwardly protruding from the extension portion of the top housing.

According to various embodiments, the hinge comprises two apertures defined by two parts protruding from the top housing and another two apertures defined by another two parts protruding from the bottom housing.

According to various embodiments, a pin extends through the apertures.

According to various embodiments, the hinge comprises two retaining clips mounted on opposing ends of the pin.

According to various embodiments, the bottom housing comprises an upper surface and the bosses are raised above the upper surface.

According to various embodiments, the sensor sits on at least one of the bosses such that no portion of the sensor contacts the upper surface of the bottom housing.

According to various embodiments, the sensor comprises a bolt connector defining a bolt aperture and a nut fitted inside the bolt aperture.

According to various embodiments, the nut is longer than the bolt aperture such that a lower surface of the nut protrudes from the bolt aperture.

According to various embodiments, the lower surface of the nut sits directly on the boss.

According to various embodiments, the bosses are offset such that the bosses are not collinear along a line extending parallel to the hinge.

According to various embodiments, the assembly includes an electrical connector engaged to the sensor, the electrical connector including a primary portion and a cord; wherein the top and bottom housings are sized to cover the sensor, the primary portion of the electrical connector, and only a portion of the cord.

According to various embodiments, the top housing comprises a plurality of outer ribs.

According to various embodiments, the ribs engage an upper sealing surface of the bottom housing when the top housing is in the closed position.

According to various embodiments, the assembly includes an attachment ribbon with a flexible extension and a hoop.

According to various embodiments, the triangular portions smoothly and continuously narrow into the rectangular extension portions such that the narrows do not define edges.

For a better understanding of the invention, reference may be made to embodiments shown in the following drawings. The components in the drawings are not necessarily to scale and related elements may be omitted, or in some instances proportions may have been exaggerated, so as to emphasize and clearly illustrate the novel features described herein. According to some embodiments, non-perspective views are to scale. In addition, system components can be variously arranged, as known in the art. Further, in the drawings, like reference numerals designate corresponding parts throughout the several views.

FIG. 1 is a front perspective view of a sensor.

FIG. 2 is a rear perspective view of the sensor.

FIG. 3 is a top plan view of the sensor.

FIG. 4 is a front perspective view of the sensor with a nut.

FIG. 5 is a side perspective view of the sensor with a bolt.

FIG. 6 is a front perspective view of a first cover.

FIG. 7 is a top plan view of the first cover.

FIG. 8 is a bottom plan view of the first cover.

FIG. 9 a is a front perspective view of the first cover mounted to the sensor.

FIG. 9 b is a side plan view of the first cover mounted to the sensor.

FIG. 9 c is a bottom plan view of the first cover mounted to the sensor.

FIG. 10 is a front perspective view of a second cover.

FIG. 11 is a side plan view of the second cover.

FIG. 12 is a bottom plan view of the second cover.

FIG. 13 is a bottom perspective view of the second cover mounted to the sensor.

FIG. 14 is a side perspective view of the second cover mounted to the sensor.

FIG. 15 is a side perspective view of the first or second cover mounted to the sensor.

FIG. 16 is a front perspective view of a third cover.

FIG. 17 is a front perspective view of a fourth cover.

FIG. 18 is a top plan view of the fourth cover.

FIG. 19 is a side plan view of the fourth cover.

FIG. 20 is a front plan view of the fourth cover.

FIG. 21 is a bottom plan view of the fourth cover.

FIG. 22 is a top perspective view of a bottom housing of the fourth cover.

FIG. 23 is a side perspective view of the fourth cover mounted to the sensor.

While the invention may be embodied in various forms, there are shown in the drawings, and will hereinafter be described, some exemplary and non-limiting embodiments, with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.

In this application, the use of the disjunctive is intended to include the conjunctive. The use of definite or indefinite articles is not intended to indicate cardinality. In particular, a reference to “the” object or “a” and “an” object is intended to denote also one of a possible plurality of such objects. Further, the conjunction “or” may be used to convey features that are simultaneously present, as one option, and mutually exclusive alternatives as another option. In other words, the conjunction “or” should be understood to include “and/or” as one option and “either/or” as another option.

FIGS. 1 to 3 generally shows and illustrates a sensor 10 . The sensor 10 may include internal electronic components configured to measure a dimension, such as yaw. As shown in FIG. 1 , the sensor 10 includes (a) a power supply portion 11 (also referred to as a power supplier 11 ), (b) a bolt connection portion 12 (also referred to as a bolt connector 12 ), (c) an anti-rotation portion 13 (also referred to as anti-rotator 13 ), and (d) a main housing portion 14 (also referred to as main housing 14 ).

The power supply portion 11 is configured to receive a female power supply connector 16 as shown in FIG. 5 . More specifically, the female power supply connector 16 slides over rails 11 a , 11 b , 11 c , and 11 d until approximately reaching the main housing portion 14 . As shown in FIG. 1 , the rails 11 a , 11 b , 11 c , and 11 d are flush with a terminal end of the power supply portion 11 . The female power supply connector 16 includes one or more first power terminals that extend into power receiving slot 11 e . The power receiving slot 11 e includes one or more second power terminals that engage with the one or more first power terminals. The female power supply connector 16 thus provides electrical energy to the sensor 10 .

The bolt connection portion 12 is configured to receiving a bolt 17 (see FIG. 5 ) therethrough to bind the sensor 10 to a separate structure (e.g., a vehicle or a trailer for a vehicle). The bolt connection portion 12 includes a bolt and bushing hole 12 a , a first cover rail 12 b , a cylindrical protrusion 12 c , and a planar surface 12 d . The cylindrical portion 12 c cooperates with the planar surface 12 d to define the bolt and bushing hole 12 a.

The anti-rotation portion 13 is configured to fit into and snap against a corresponding anti-rotation feature (not shown) included on the separate structure (e.g., the vehicle or the trailer for the vehicle). The anti-rotation portion 13 prevents the sensor 10 from twisting or rotating while a user tightens the bolt in the bolt and bushing hole 12 a . The anti-rotation portion 13 a includes a tongue 13 a , a lip 13 b , and pillars 13 c . Upon insertion into the corresponding anti-rotation feature, the tongue 13 a and the lip 13 b bend backwards until the lip 13 b reaches a lip recess of the corresponding anti-rotation feature. Upon reaching the lip recess, the tongue 13 a and the lip 13 b snap forward and the lip 13 b engages the lip recess. The anti-rotation feature is shaped as a slot that generally matches the outer perimeter defined by the pillars. As shown in FIG. 1 , the outer perimeter of the pillars generally defines an oval shape. Therefore, the anti-rotation feature is an oval-shaped slot.

The main housing portion 14 contains the internal electronic components of the sensor 10 . The main housing portion 14 includes a second cover rail 14 a , a third cover rail 14 b , a rectangular housing portion 14 c , and a shoulder portion 14 d . The internal electronic components of the sensor sit inside the rectangular housing portion 14 c.

FIG. 4 generally shows and illustrates the sensor 10 with a nut 15 positioned in the bolt and bushing hole 12 a . The nut 15 includes a bolt hole 15 a , a bottom nut protrusion 15 b , and a top nut protrusion 15 c . According to various embodiments, one or both of the bottom nut protrusion 15 b and the top nut protrusion 15 c vertically extend (i.e., protrude) out of the bolt and bushing hole 12 a . The bottom nut protrusion 15 b protrudes from the bottom of the bolt and bushing hole 12 a . The top nut protrusion 15 c protrudes from the top of the bolt and bushing hole.

FIG. 5 shows the sensor 10 ( a ) connected to the female power supply connector 16 and (b) receiving a bolt 17 and a washer 18 . The bolt 17 extends through the bolt hole 15 a of the nut 15 . The washer 18 sits on one or both of the top nut protrusion 15 c and the planar surface 12 d.

FIGS. 6 to 9 show a first generic cover 100 for the sensor 10 . The first generic cover 100 includes features (discussed below) that may appear on some or all of the other cover embodiments discussed below. The first generic cover 100 is configured to slip over the top of the sensor 100 .

The first generic cover 100 includes a bolt hole 100 a , a curved portion 100 b sized to accommodate the bolt connection portion 12 of the sensor 10 , a corner portion 100 c sized to accommodate the main housing portion 14 of the sensor 10 , a U-shaped garage portion 100 d sized to accommodate a portion of the power supply portion 11 , a first slot 100 e sized to accommodate the first cover rail 12 b , a second slot 100 f sized to accommodate the second cover rail 14 a , and a third slot 100 g sized to accommodate the third cover rail 14 b.

As shown in FIGS. 9 a to 9 c , some or all of the interior walls of the curved portion 100 b , the corner portion 100 c , and the garage portion 100 d contact corresponding exterior surfaces of the sensor 10 . Thus, the inner perimeter of some or all of the curved portion 100 b , the corner portion 100 c , and the garage portion 100 d match (e.g., are flush against) some of the outer perimeter of the sensor 10 . As shown in FIGS. 9 b and 9 c , the first generic cover 100 exposes (i.e., does not cover) the cylindrical protrusion 12 c of the sensor 10 , the anti-rotation portion 13 of the sensor 10 , and some or all of the rails 11 a to 11 d (e.g., at least rail 11 b is exposed) of the sensor 10 .

The first slot 100 e , the second slot 100 f , and the third slot 100 g discourage the first generic cover 100 from twisting or rotating with respect to the sensor 10 . The bolt hole 100 a is optional since in some embodiments, the bolt 17 and the washer 18 are secured to the sensor 10 prior to dropping the first generic cover 100 on the sensor 10 .

As previously stated, some or all of the features of the first generic cover 100 are common or generic to other embodiments of the cover. More specifically, other embodiments of the cover may include the slots 100 e , 100 f , and 100 g , and the bolt hole 100 a . The other embodiments over the cover may also include inner perimeters that match (e.g., are flush against) some of the outer perimeter of the sensor 10 . The other embodiments may expose (i.e., not cover) the cylindrical protrusion 12 c of the sensor 10 , the anti-rotation portion 13 of the sensor 10 , and some or all of the rails 11 a to 11 d (e.g., at least rail 11 b is exposed) of the sensor 10 .

FIGS. 10 to 14 generally shows and illustrate a second cover 200 . The second cover 200 , similar to the first generic cover 100 , includes a curved portion 200 b sized to accommodate the bolt connection portion 12 of the sensor 10 , a corner portion 200 c sized to accommodate the main housing portion 14 of the sensor 10 , and a U-shaped garage portion 200 d sized to accommodate a portion of the power supply portion 11 .

The illustrated second cover 200 does not include a bolt hole, although various embodiments may include a bolt hole similar to the bolt hole 100 a of the first generic cover 100 . The second cover 200 includes a first snap slot 200 e , a second snap slot 200 f , and a slot 200 g . The snap slots 200 e and 200 f include a snap fit feature similar to the anti-rotation portion 13 of the sensor 10 . Each snap fit feature includes a tongue and a lip, similar to the tongue 13 a and lip 13 b of the sensor 10 . The tongue of each snap fit feature is recessed from an inner perimeter 201 of the second cover 200 to receive the first and second cover rails 12 b and 14 a . The lip of each snap fit feature snaps to and grasps an underside of the first and second cover rails 12 b and 14 a . The slot 200 g is substantially similar to the third slot 100 g of the first generic cover 100 .

FIG. 13 generally shows and illustrates a tongue 202 a and a lip 202 b of the snap fit feature of the second snap slot 200 f . The lip 202 b has snapped on to and grasped the underside of the second cover rail 14 a of the sensor 10 . As shown in FIG. 11 , the snap fit features of the snap slots 200 e and 200 f need not be identical. For example, and as shown in FIG. 11 , the tongue of the snap fit feature of the second snap slot 200 f is shorter than the tongue of the snap fit feature of the first snap slot 200 e . The lips of the snap fit features may be identical. The disparity in length of the tongues may advantageously discourage the cover 200 from flipping (i.e., rotating about an axis parallel and extending through the power receiving slot 11 e ). Snap slot 200 e opposes snap slot 200 f , which advantageously discourages both of the snap slots 200 e and 200 f from disengaging during use (e.g., rotation and disengagement of one snap slot 200 e or 200 f is opposed by the opposing snap slot 200 f or 200 e ).

FIG. 14 shows the second cover 200 attached to the sensor 10 , which is secured to the female power supply connector 16 .

FIG. 15 shows the first generic cover 100 or the second cover 200 mounted on the sensor 10 via a bolt 17 , and a second washer 19 . The bolt 17 extends through the nut 15 , the washer 18 (not shown), and the second washer 19 . The second washer 19 includes a threaded portion 19 a and a plate portion 19 b . The threaded portion 19 a has an outer hexagonal surface that enables tightening of the cover 100 , 200 with respect to the sensor 10 . The plate portion 19 b distributes load across a top surface of the cover 100 , 200 .

FIG. 16 shows a third cover 300 . The third cover 300 is similar to the first generic cover 100 and the second cover 200 . The garage portion of the third cover, however, extends further than the garage portions 100 d , 200 d of the first and second covers 100 , 200 . More specifically, the garage portion 300 d of the third cover 300 extends to cover the power supply portion 11 of the sensor 10 , when the third cover 300 is dropped over the sensor 10 . The third cover 300 may include some or all of the internal features of the first and second covers 100 , 200 , including the slots 100 d , 100 e , 100 f and/or the snap slots 200 e , 200 f.

As shown in FIG. 16 , the third cover 300 includes an attachment ribbon 301 . The ribbon 301 includes an attachment point 301 a , a flexible extension 301 b , and a hoop 301 c . The hoop 301 c is sized to fit around a cylindrical cable 16 b of the female power supply connector 16 , as opposed to a primary portion 16 a of the female power supply connector 16 . During manufacturing, an engineer may place the hoop 301 c about the cylindrical cable of the female power supply connector 16 , and then connect the cylindrical cable of the female power supply connector 16 to a power source (e.g., a battery). The attachment ribbon enables a user to remove the third cover 300 from the sensor 10 , without the third cover 300 falling to the ground and thus picking up dirt or debris. It should be appreciated that some or all of the other embodiments of the cover may include the attachment ribbon 301 .

FIGS. 17 to 23 generally show and illustrate a fourth cover 400 , which is shaped and dimensioned to cover both the top and bottom of the sensor 10 while leaving space for the female power supply connector 16 . The fourth cover 400 includes a top housing 400 a joined to a bottom housing 400 b along an interface 400 c . The interface 400 c may be a flexible gasket joined to the top housing 400 a or the bottom housing 400 b.

With reference to FIG. 23 , the top housing 400 a may include a plurality of outer ribs 412 . The lower-most outer rib 412 may engage with an upper sealing surface 413 of the bottom housing 400 b . The outer ribs 412 enhance the strength of the engagement between the top housing 400 a and the bottom housing 400 b . The flexible gasket, if present, may be joined to the upper sealing surface 413 of the bottom housing 400 b or the outer ribs 412 of the top housing 400 a.

With reference to FIG. 18 , the top housing 400 a is rotatable about the bottom housing 400 b via a joint or hinge 400 d . FIG. 23 shows the top housing 400 a in the rotated or open position. FIGS. 19 and 20 show the top housing 400 a in the closed position (i.e., interfacing with bottom housing 400 b ). The joint or hinge 400 d may be a pin hinge 400 d with a pin 401 disposed through four retainers 402 , 403 , 404 , and 405 . First retainer 402 and fourth retainer 405 are identically shaped and integral with and projected from the bottom housing 400 b . Second retainer 403 and third retainer 404 are identically shaped and integral with and projected from the top housing 400 a . The retainers 402 to 405 have a flat rectangular shape. Each retainer 402 to 405 defines an aperture sized to accommodate the pin 401 . According to some embodiments, the apertures of each retainer 402 to 405 are identically sized. After fitting the pin 401 through the apertures of the retainers 402 to 405 , plastic retaining clips may be connected to the opposing ends of the pin 401 to prevent the pin 401 from disengaging from any of the retainers 402 to 405 .

With continued reference to FIG. 18 , the top housing 400 a includes a triangular portion 406 a that narrows into a rectangular extension portion 406 b . It should be appreciated that narrowing portion is curved (i.e., does not include sharp edges) to enhance strength. The extension portion 406 b defines a plurality of first terminal surfaces 407 , including a hood 407 b . It should be appreciated that the triangular geometry of the top housing 400 a provides room for the sensor while restricting the amount of room for the female power supply connector 16 and thus ingress of water or dirt.

Turning to FIG. 20 , the first terminal surfaces 407 of the top housing 400 a are generally configured to mate or engage with second terminal surfaces 408 of the bottom housing 400 b . Engagement of the first and second terminal surfaces 407 , 408 discourages the top housing 400 a from rotating with respect to the bottom housing 400 b while the vehicle is in motion.

As shown in FIG. 20 , the first terminal surfaces 407 include a first upper rounded portion 407 a and a second upper rounded portion 407 c separated by the hood 407 b . The first upper rounded portion 407 a transitions into a first upper indented portion 407 d having a first inward indentation or bend. The second upper rounded portion 40 c transitions into a second upper indented portion 407 e having a second inward indentation or bend.

The second terminal surfaces 408 include a U-shaped lower portion 408 a that transitions into (a) a first lower indented portion 408 b having a first outward indentation or bend and (b) a second lower indented portion 408 c having a second outward indentation or bend.

As shown in FIG. 20 , the first inward indentation engages the first outward indentation and the second inward indentation engages the second outward indentation when the top housing 400 a is in the closed position. The outward indentations are located about the inward indentations, thus discouraging or inhibiting upward rotation of the top housing 400 a with respect to the bottom housing 400 b . As a result, the fourth cover 400 includes a dual snap feature.

With reference to FIG. 21 , the bottom housing 400 b includes a triangular portion 410 a that narrows into a rectangular extension portion 410 b . It should be appreciated that narrowing portion is curved (i.e., does not include sharp edges) to enhance strength. The triangular portion 410 a defines a first aperture 400 b - 1 and a second aperture 400 b - 2 . The apertures are offset from each other (e.g., are not collinear along a line parallel to the pin 401 ). More specifically, the first aperture 400 b - 1 is closer to the joint 400 d than the second aperture 400 b - 2 .

With reference to FIG. 22 , the bottom housing 400 b includes a boss with raised circular ribs 409 a surrounding the first aperture 400 b - 1 and a second boss with raised circular ribs 409 b surrounding the second aperture 400 b - 2 . The raised ribs of the bosses (a) enhance strength and/or toughness of the surfaces defining the apertures and (b) elevate the sensor 10 and the female power supply connector 16 from an upper surface 411 of the bottom housing 400 b . Elevation advantageously enables the sensor 10 to remain dry if water breaches the fourth cover 400 and floods the upper surface 411 of the bottom housing 400 b . According to some embodiments, the upper surface 411 of the bottom housing 400 b defines a plurality of drains (not shown) to expel water.

FIG. 23 shows the sensor 10 installed in the fourth cover 10 . The sensor 10 (and thus the female power supply connector 16 ) are elevated above the upper surface 411 of the bottom housing by virtue of the boss 409 a . More specifically, and with reference to FIG. 4 , the bottom nut protrusion 15 b sits on top of the first boss 409 a . The bolt 17 extends through the first aperture 400 b - 1 . A second bolt 20 extends through the second aperture 400 b - 2 . This sensor 10 may lack the anti-rotation portion 13 . According to other embodiments, the sensor 10 includes the anti-rotation portion 13 and the bottom housing 400 b defines a suitable void to accommodate the anti-rotation portion 13 . As shown in FIG. 23 , the top housing 400 a and the bottom housing 400 b are dimensioned to fully enclose the sensor 10 and the primary portion 16 a of the female power supply connector 16 .

It should be appreciated that the polarity of the indentations is reversed in FIG. 23 . More specifically, the top housing 400 a now includes outward indentations and the bottom housing 400 b now includes inward indentations. The outward indentations of the top housing 400 a sit below the inward indentations of the bottom housing 400 b such that the first terminal surfaces 407 are partially encompassed or surrounded by the second terminal surfaces 408 .