Roof Sensor Module for self-driving cars
As a leading polymer company, we supported Webasto with polycarbonate expertise and processing know-how during the development of the RSM cover. The cover must meet stringent mechanical requirements while offering an aesthetic exterior design with sensor transparent windows. Additionally, it had to provide the necessary design freedom for embedding electronic components and fixation elements.
The primary challenge was to develop a cover that could seamlessly integrate multiple sensors while maintaining optimal performance and durability. The cover had to be highly permeable to sensor signals, such as those from LiDARs and cameras, while also offering thermal management capabilities to prevent overheating and ensure reliable sensor operation. Furthermore, the cover needed to be resistant to adverse weather conditions, ensuring flawless operation, e.g., in extreme high or low temperatures.
Makrolon®AG meets our requirements and enables the cover to retain its shape even in high temperatures without impairing roof sensor module functions.
Our solution involves a two-component injection compression molding process. The first shot is made from the transparent polycarbonate Makrolon® AG, which is highly permeable to various sensor signals.
For the second shot, the black, mineral-filled PC-ABS Bayblend® T95 MF is being used. Thanks to the combination of both materials, the roof module meets high mechanical requirements and at the same time offers an attractive glass-like exterior design and sensor transparency. The high heat resistance of polycarbonate ensures that the cover retains its shape even in high temperatures, without impairing sensor function.
A colored Makrofol® ST film brings decoration and function in while maintaining excellent LiDAR, NIR signal permeability.
Webasto’s Roof Sensor Module combines optimal sensor performance with outstanding aesthetic design.
Key benefits
- Function Integration Back-molded heater on film. Fixation elements formed in the second shot.
- High Sensor Transparency Transparent polycarbonate Makrolon® AG is highly permeable to LiDAR signals.
- Aesthetic design Aesthetic design with glass-like surfaces and transparent windows.
- High Heat distortion temperature Dimension stability ensuring flawless operation, e.g., in extreme high or low temperatures.
- Robust and high impact strength Protection for embedded electronic components.
