GB2582755A

GB2582755A - A vehicle body member comprising a sensor array

Info

Publication number: GB2582755A
Application number: GB1904408.0A
Authority: GB
Inventors: Tomar Ashutosh
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2019-03-29
Filing date: 2019-03-29
Publication date: 2020-10-07
Anticipated expiration: 2039-03-29
Also published as: GB2582755B; GB201904408D0

Abstract

A vehicle body member comprising an ultrasonic sensor array and a method of making the device. The sensor on the vehicle body member comprises a substrate 202, wherein the substrate is the vehicle body member or arranged to be attached to a vehicle body member. The substrate having at least one electrically conductive pathway 104 attached to its surface including one or more contact elements 106. At least one piezo electric film 108 in electrical contact with the one or more contact elements forms the ultrasonic elements making up the array. The vehicle body member or the substrate may comprise one or more cavities 204, the contact elements being coincident with the cavities. The cavities preferably being configured to reflect an anti-phase wave to the ultrasonic elements. The conductive pathways preferably have at least a portion arranged in a digitated (fig 3A) or interdigitated (fig 3B) structure.

Description

A Vehicle Body Member Comprising a Sensor Array

TECHNICAL FIELD

Aspects of the invention relate to a vehicle body member comprising a sensor array, to a method of making such and a vehicle comprising such.

BACKGROUND

It is known to mount sensors on a vehicle body panel, i.e. on the exterior of a vehicle.

Such sensors may include parking sensors or cameras. However, such sensors can be limited in their functionality and/or resolution, amongst other factors.

It is an object of embodiments of the invention to at least mitigate one or more of the problems of the prior art and/or to provide improvements generally.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention may be understood with reference to the 20 appended claims.

In an aspect, there is a vehicle body member comprising an array of ultrasonic elements. The vehicle body member comprises a substrate, wherein the substrate is the vehicle body member or the substrate is arranged to be attached to the vehicle body member. There is at least one electrically conductive pathway comprising one or more contact elements, the conductive pathway is attached to a surface of the substrate. There is at least one piezo electric film in electrical contact with the one or more contact elements to form one or more ultrasonic elements of the array of ultrasonic elements.

This allows an array of ultrasonic elements may be arranged on a vehicle body member with closely spaced individual ultrasonic elements. This allows a large number of ultrasonic elements to be arranged on a vehicle body member. Increasing the number of elements in an ultrasonic array may allow the array to perform sensing with a very high resolution. It may also enable the array to perform multiple functions. Furthermore, because each ultrasonic element is formed with a conductive pathway arranged onto the surface of the substrate, conventional wiring is not required. This means the vehicle body panel is lighter and requires less volume of the vehicle to be occupied by wires when compared to conventional systems.

The term ultrasonic element refers to but is not limited to an element capable of converting an electrical signal into an ultrasonic wave and/or is capable of converting an incident vibrational wave into an electrical signal. Thus, the ultrasonic element may be any element that functions as an ultrasonic receiver, an ultrasonic transmitter or both (a transceiver). The ultrasonic elements may function to emit and/or receive waves normal to the surface of the vehicle body member.

In embodiments, the substrate may comprise a surface comprising one or more cavities. A cavity may be formed as an indentation into the surface, or may be formed from material raised above the surface that encompasses a cavity. In embodiments, the one or more contact elements may be coincident with the one or more cavities.

The cavities may be used to favourably affect properties of the ultrasonic waves created or attenuated by the ultrasonic elements.

In embodiments, the one or more cavities may be configured to reflect a coherent wave to the one or more ultrasonic elements, when the ultrasonic elements are operated at an operation frequency. The coherent wave may be an antiphase wave. A coherent wave may be used to further modify waves or attenuate undesirable waves produced by an ultrasonic element. In particular, anti-phase waves may be used to attenuate waves directed into the vehicle body member from an ultrasonic element by wave superposition.

In embodiments, at least a portion of the conductive pathway may be arranged as a digitated structure on the surface of the substrate. This may provide an arrangement that further improves the spacing between elements. Reducing the spacing may further improve the number of elements that can be achieved per area of substrate.

In embodiments, at least two portions of the conductive pathway may be arranged as an interdigitated structure. This may provide an arrangement that further improves the spacing between elements.

In embodiments, the conductive pathway may comprise at least two portions separated by the piezo electric film. This may provide an arrangement that further improves the spacing between portions of conductive pathways and therefore, improve the number of elements that can be achieved per area of substrate.

In embodiments, the vehicle body member may comprise at least one layer of elastomeric paint.

In embodiments, the piezo electric film may comprise a single continuous film. This may further improve ease of construction.

In embodiments, the vehicle body member may be a front or rear vehicle bumper.

In an aspect, a vehicle may comprise a vehicle body member according to any of the other aspects or embodiments described herein.

In an aspect, a method of making a vehicle body member with an array of ultrasonic elements, comprises providing at least one electrically conductive pathway on a surface of a substrate, the conductive pathway comprising one or more contact elements. The method comprises applying a piezoelectric film to form an electrical contact with the one or more contact elements, wherein the substrate is shaped as the vehicle body member before the at least one electrically conductive pathway is provided on the surface of the substrate, or the substrate is attached to the surface of a vehicle body member after the at least one electrically conductive pathway is provided on the surface of the substrate, or the substrate is a preform that is shaped as the vehicle body member after the at least one electrically conductive pathway is provided on the surface of the substrate.

In embodiments, the at least on electrically conductive pathway may be printed onto the surface of the substrate, for example by way of mechanical printing, inkjet printing or screen printing, vapor deposition, spray deposition, spluttering, etching, precipitating, or laser sintering/deposition, etc. In embodiments, one or more cavities may be formed on a surface of the vehicle body member or substrate.

In embodiments, providing a conductive pathway on the surface of the substrate may comprise providing the conductive pathway so that the one or more of the contact elements are coincident with the one or more cavities.

In embodiments, elastomeric paint may be applied to one or more of: the piezoelectric film, the conductive pathway or the substrate.

In embodiments, providing a conductive pathway on the surface of the substrate may comprises providing at least a portion of the conductive pathway as a digitated structure.

In embodiments, the method may comprise providing a second conductive pathway or a second portion of a conductive pathway as a digitated structure, interdigitated with a first digitated structure.

In embodiments, the method may comprise providing a second conductive pathway or a second portion of a conductive pathway onto the piezo electric film.

In embodiments, the substrate may be shaped as a vehicle bumper or the substrate may be applied to a member shaped as a vehicle bumper.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of example only, with reference to the accompanying figures.

Figure 1A and 1B show cross-section representations of embodiments of a vehicle body members comprising a sensor arrays.

Figure 2 shows a cross-section representation of an alternative embodiment of a vehicle body member comprising a sensor array.

Figure 3A and 3B show a planform representations of embodiment vehicle body members comprising a sensor arrays.

Figure 4 shows a representation of an alternative embodiment of a vehicle body member comprising a sensor array.

Figure 5 shows a representation of a vehicle according to an embodiment.

Figure 6A-C shows embodiment methods for making a vehicle body member with an integrated array of ultrasonic transducers.

Figure 7 illustrates a simplified example of the control system for controlling a sensor array.

DETAILED DESCRIPTION

Before describing several embodiments of the invention, it is to be understood that the invention is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the invention is capable of other embodiments and of being practiced or being carried out in various ways.

The term "vehicle' used herein, may refer to but is not limited to automobiles. The term vehicles may comprise automobiles with SUV, saloon or estate body types, amongst others. The term vehicle may comprise combustion or electrically propelled vehicles. The term vehicle may comprise user driven or self-driven vehicles. A vehicle may have a forward direction and a rear direction opposite thereto. The forward direction is aligned with the normal direction of travel of the vehicle. A vehicle may have a front, rear and side ends. The front end is the end facing in the forward direction.

The term "vehicle body member" used herein, may refer to a body panel of a vehicle, this may comprise an external surface of a vehicle. A non-limiting example of a vehicle body member comprise a bumper of an automobile.

The term "ultrasonic element" used herein may refer to an element capable of converting an electrical signal into an ultrasonic wave and/or capable of converting a mechanical input into an electrical signal. The term "ultrasonic element" used herein may comprise ultrasonic receivers, transmitters or transceivers. A non-limiting example of an "ultrasonic element" comprises a piezo electric element.

The term "ultrasonic" used herein, may pertain to a sonic wave of a frequency higher that the human upper audible limit. For example, an ultrasonic wave may comprise a propagating mechanical vibration of the order of 20 kHz or higher.

The term "array" used herein in reference to ultrasonic elements may refer to but is not limited to an arrangement of multiple ultrasonic elements. For example, the array may comprise elements in a one-dimensional linear arrangement or two-dimensional grid arrangement. The spacing of the elements, may be regular, irregular or regularly offset.

The term "substrate" used herein, may refer to but is not limited to any substance or material to which or in which a conductive pathway may be applied.

The term "conductive pathway" used herein may refer to but is not limited to any electrically conductive pathway. Non-limiting examples comprise wiring, electrically conductive tracks and solder amongst others. A particular but non-limiting example of a conductive pathway comprises tracks formed from screen printing electrically conductive ink.

The term "film" used herein, may refer to but is not limited to a sheet material of 500 micrometres thickness or less.

The term "electrical contact" used herein, may refer to but is not limited to a contact between two objects sufficient to conduct electricity to an extent suitable for use with electronics.

The term "anti-phase" used herein, may refer to but is not limited to a wave having a phase of ±180 ° of another wave. The term "anti-phase" used herein, may be used in reference to attenuation of waves via coherent wave superposition.

The term "preform" used herein, may refer to an object in its preliminary form, before it undergoes a final shaping process. For example, a flat polymer sheet prior to press moulding into a vehicle body component.

The term "digitated" used herein, may refer to an arrangement comprising substantially parallel fingers, for example a in a comb-like arrangement. The term "interdigitated" used herein, may refer to two opposed digitated structures. In particular, the term may refer to an arrangement where the parallel fingers of one digitated arrangement are positioned in the spacing between parallel fingers of a second digitated structure.

Referring to Figure 1A, an embodiment vehicle body member with a sensor 100 attached thereto is shown in cross section. The vehicle body member comprises a body panel 102 providing a substrate. An electrically conductive pathway is attached to a top surface of the panel 102. The conductive pathway in the illustrated embodiment comprises a conductive track 104. A portion of the conductive track 104 functions as a contact element 106. A piezo electric film 108 is placed over at least a portion of the track 104 and substrate panel 102, and is in electrical contact with the contact element 106.

The body panel 102 of the vehicle body member in figure 1A is shown as the substrate to which the track 104 and piezoelectric film 108 are applied. Thus, in this embodiment, the substrate is also the vehicle body member. However, it is envisioned that the present invention may also encompass embodiments where the substrate is a separate component that is adapted to be attached to a vehicle body member, as shown in figure 1B. In figure 1B, the conductive track 104 is attached to a separate substrate layer 102'. The substrate layer 102' is shown in figure 1B attached to a surface of the body panel 102 the vehicle body member.

In accordance with the embodiment shown in figure 1A, the substrate 102 may be a vehicle body member. A non-limiting example of a body panel 102 that is a vehicle body member may comprise a polymer front bumper panel for an automobile. A conductive pathway 104 and piezo electric film 108 then may be applied to the surface of the bumper panel. Alternatively, and in accordance with the embodiment shown in figure 1B, the substrate 102' may comprise a sheet or layer of material to which the conductive pathway 104 and piezo electric film 108 are applied. The substrate 102' itself may then be attached to a vehicle body member such as the body panel 102. In a further non-limiting example, the substrate 102' may be a polymer film with an adhesive backing that is adhered to a vehicle body member (e.g. a front bumper panel) before or after the conductive pathway 104 and optionally the piezo electric film 108 has been applied. In both variants embodied by figures 1A and 1B, the substrate 102, 102' functions as a medium to which the conductive pathway 104 and piezo electric film 108 are applied.

The conductive pathway 104 may be provided by any electrically conductive medium that can be applied to a substrate 102, 102'. For example, the conductive pathway 104 may comprise a metallic strip, wiring, or any other element capable of conducting an electrical signal. The conductive pathway 104 may be printed, embedded, adhered, etched into the surface or applied to the substrate by any other known method. Any number of conductive pathways may be applied to the substrate. The term "electrically conductive" may be considered as having a sufficient electrical conductivity to be suitable for use as part of electronic circuitry.

The conductive pathway comprises a plurality of contact elements 106. A contact element 106 may be at least a portion of the conductive pathway 104 that electrically contacts the piezo electric film 108. Thus, the conductive pathway 104 functions to transmit electrical signals to and/or from the piezo electric film 108 via the contact elements 106. The contact elements 106 may therefore be considered as electrodes contacting the piezo electric film 108.

In embodiments, the conductive pathway 104 may be shaped, insulated or otherwise arranged to prevent unwanted portions of the conductive pathway 104 from electrically connecting to the piezo electric film 108. For example, an electrically insulating barrier may be placed over portions of the conductive pathway to electrically insulate it from the piezo electric film 108. Alternatively, the piezo electric film 108 may only be deposited on the contact elements 106, so that no electrical connection is formed with the remainder of the conductive pathway 104. Alternatively, the conductive pathway 104 may be arranged away from the piezo electric film 108, by e.g. by embedding within the substrate 102, 102' or arranging on an opposite surface of the substrate. The contact elements 106 may be portions of the conductive pathway 104 that are shaped, uninsulated or otherwise arranged to electrically connect to the piezo electric film 108.

In embodiments, the conductive pathway 104 may comprise a pathway comprising one or more of nickel, silver, copper, gold, ink, indium tin oxide, carbon, doped semiconductors, conductive polymers (e.g. PEDOT), or inks comprising any of the former.

The piezoelectric film 108, may comprise a single film applied to the substrate 102 in electrical contact with a plurality of contact elements 106. Alternatively, the piezo electric film may comprise any number of discrete films that are applied to the substrate to make electrical contact with one or more contact elements 106. A piezo electric film may be a thin piece (e.g. between 10 and 300 micrometres) of piezo electric material, which may become strained when an electric field is applied. The piezo electrical film 108 may also generate an electrical charge or potential in response to an applied mechanical stress.

The piezo electric film 108 may comprise a piezo-crystal, piezo-ceramic, piezo-polymer or a hybrid piezo-material. Non-exhaustive examples may comprise quartz, lead zirconate, PVT, semiconductor crystals such as Group III-VI and II-V materials, polyvinylidene fluoride or any other known piezoelectric material. In particular embodiments, the piezoelectric film may comprise polyvinylidene fluoride or a copolymer of vinylidene fluoride and trifluoroethylene. The piezo electric film may comprise a piezoelectric polymer cast as a film less than 500 micrometres thick, or between 10 and 300 micrometres thick, or between 20 to 200 micrometres thick or between 40 and 100 micrometres thick, and or any range comprising any combination of the aforesaid values.

In Figure 1, the piezo electric film 108 is shown over the conductive pathway 104, however, the piezo electric film 108 may alternatively be arranged against the substrate and one or more conductive pathways 104 arranged over the piezo electric film 108.

The piezo electric film 108 may be caused to generate a sonic wave by applying one or more electrical signals to the conductive pathway 104. The contact elements 106 of the conductive pathway 104 may transfer the electrical signal(s) to the piezo electric film 108, causing the piezo electric film 108 to mechanically deform. This mechanical deformation may be induced at frequencies and amplitudes sufficient to generate an ultrasonic wave. Thus, an electric signal may be applied to actuate the piezo electric film, to create an ultrasonic wave. As such the conductive pathways 104, contact elements 106 and piezo electric film 108 collectively form ultrasonic element. The ultrasonic element may emit an ultrasonic wave in a direction that is generally perpendicular to the surface that they are applied to. The piezo electric film 108 may also be mechanically deformed by an incident vibrational wave. Mechanical deformation of the piezo electric film 108 may generate a voltage potential in the piezo electric material, which may result in the generation of an electric signal transmitted in the conductive pathway 104 via contact element 106. Thus, an electric signal may also be created by an incident vibrational wave.

Where the contact element 106 contacts the piezo electric film 108, the resulting arrangement may function to create and or detect vibrational waves. The piezo electric film 108 may function as an ultrasonic transmitter by converting an electrical signal to an ultrasonic wave. Similarly, the piezo electric film 108 may function as an ultrasonic receiver by converting an incident vibrational wave to an electrical signal. Optionally, the piezo electric film 108 may function as an ultrasonic transceiver by being operable to perform both transmitting and receiving functions. An array of ultrasonic elements, each comprising a conductive pathway 104, contact elements 106 and piezo electric film 108 as hereinbefore described, may function as an array of emitters, receivers or sensors. An individual ultrasonic element may be considered as an individual emitter, receiver or sensor.

A sensor 100 of the invention may contain any number of such ultrasonic elements.

Vehicle body members may be produced comprising many ultrasonic elements. For example, a vehicle body panel, such as an automobile bumper, may comprise at least 10, 50, 100, 200, 500 or 1000 ultrasonic elements. Fitting conventional ultrasonic elements, such as conventional parking distance sensors, to a vehicle body member requires a substantial amount of wiring, which prohibits the fitting of ultrasonic elements in large numbers. However, the ultrasonic elements hereinbefore described of the sensor 100 may be applied with a smaller spacing between the elements than would otherwise be possible with conventional ultrasonic elements. The ultrasonic elements of the sensor 100 may be arranged in one-dimensional or two-dimensional arrays, these may extend along the width of a vehicle body member and/or optionally along the height of a vehicle body member. The different sensors of an array can also be mounted in different orientations, meaning the array can provide greater sensor coverage, and may be used for different functions.

The present invention has many advantages over existing sensors such as conventional ultrasonic parking sensors. These comprise substantially increased resolution. Improved directional discrimination, redundancy and improved visual appearance. The sensor array may also have improved functionality. In embodiments, the body panel may function as a proximity and/or parking sensor, a microphone, an audible sound emitter, a sensor to determine depth of a body of water, amongst others.

A sensor 100 of the invention can be applied to vehicle body members to form an array of sensor elements comprising a large number of individual ultrasonic elements. The sensor of the present invention provides an array having a large amount of redundancy. Therefore, the sensor may still function if some of the ultrasonic elements become damaged. Sensor elements of the invention can be closely spaced meaning they can also operate as a phased array. Because large numbers of sensor elements can be fitted to a vehicle body member, the resolution and therefore functionality is also improved over prior art water detection sensors.

Referring to figure 2, an alternative embodiment sensor 200 with an array of ultrasonic elements is shown. Similar to figure 1A, the sensor comprises a conductive pathway 104, applied to a surface of the substrate 202. A piezo electric film 108 is applied to the conductive pathway 104 to form an electrical connection with a contact element 106 of the conductive pathway 104. In the embodiment shown in figure 2, the substrate 202 is the vehicle body member. The substrate 202 further comprises one or more cavities 204. As shown in figure 2, the cavity 204 is aligned to be coincident to the contact element 106. For example, the centre of the ultrasonic element may be positioned over the centre of the cavity 204. Thus, where an ultrasonic element is formed by a contact element 106 in electrical contact with the piezo electric film 108, the cavity 204 may be arranged behind the ultrasonic element. In embodiments, the substrate may be a layer applied to a vehicle body member, in which case, the cavities 204 may be in the substrate or the vehicle body member. The cavity does not need to be limited to an indentation into the substrate or vehicle body member as shown in figure 2. The cavities may, for example, be formed from material extending above the surface of the substrate or body member, e.g. by applying material in a ring shape to the surface, or by forming the substrate/body member to comprise raised walls.

The cavities may function to provide a volume behind the piezo electric film. In embodiments, this may improve the freedom of vibration of the ultrasonic elements. The cavities 202 may also function to dampen undesirable waves reflected from the vehicle body member or substrate. The cavities may be sized so that a wave from an ultrasonic element and incident to a cavity 202, is reflected out of the cavity 202 such that when the wave returns to the ultrasonic element, it is in-phase with a wave emitted outwards from the ultrasonic element. In an embodiment, the depth of the cavity 202 may be half of the resonant wavelength of the ultrasonic element. Alternatively, the indentation may be sized to dampen or cancel the incident wave. In an embodiment, the cavity 202 may be sized to cancel the wave, or may have a volume determined with a cavity resonance selected in dependence on the resonant frequency of the ultrasonic element.

Referring to figure 3A, an embodiment vehicle body panel comprising a sensor array is 300 shown in plan form. The sensor array 300 comprises a substrate 102, onto which conductive pathways 104a 104b are arranged. The embodiment shown in figure 3 comprises two sets of conductive pathways 104a 104b, each set of pathways 104a, 104b arranged as a digitated structure, comprising parallel branches. In figure 3A, the two digitated arrangements of conductive pathways are arranged so that their parallel branches are interlocking, i.e. interdigitated. The contact elements 106 are located at the end of each of the parallel branches, with the piezo electric film 108 laid over the top of the contact elements 106. In this manner, an ultrasonic element is formed between adjacent pairs of contact elements 106 from each conductive pathway 104a, 104b. Figure 3B shows an alternative arrangement of the two conductive pathways 104a, 104b. Both pathways are arranged as an interdigitated structure, but rather than interlocking, the parallel branches are spaced apart and offset. By arranging the conductive pathways in a digitated arrangement, the contact elements can be spaced closer together allowing for a sensor with a greater density of ultrasonic elements. This in turn allows a further improvement of resolution to be achieved. The term "digitated structure" may refer to but is not limited to any arrangement comprising parallel terminal conductive pathways, i.e. shaped like a comb.

Referring to figure 4, an alternative embodiment is shown comprising a first conductive pathway 104a arranged against a surface of substrate 102. A piezo electric film 108 is arranged over the first conductive pathway 104a. A second conductive pathway 104b is arranged over the piezo electric film 108. Thus, two or more conductive pathways 104a, 104b may be separated by the piezo electric film 108. This arrangement may allow the contact elements 106 to be spaced closer together, allowing for a greater number of ultrasonic elements to be placed on the vehicle body member. In embodiments, where the conductive pathways 104a, 104b are arranged in digitated structures, the conductive pathways 104a, 104b may also be separated by the piezo electric film 108.

In embodiments, the vehicle body member may comprise an outermost elastomeric coating (not shown). For example, at least one layer of an elastomeric paint, varnish, or a protective layer. The outermost layer may comprise a layer of a lower stiffness than the underlying ultrasonic element, to prevent the layer from significantly restraining oscillation of the ultrasonic element.

Referring to figure 5, an embodiment vehicle 500 is shown. The embodiment vehicle comprises two vehicle body panels 501. each comprising an array of ultrasonic elements. The vehicle body panels 501 shown in figure 5 are front and rear bumpers, however the invention may be applied to any vehicle body panel of any suitable vehicle type, as illustrated by side panels 502.

In embodiments, the vehicle may comprise a front and/or rear bumper, wherein the front and/or rear bumper is a vehicle body panel of any aspect or embodiment described herein.

In embodiments, the vehicle may comprise a plurality of body panels comprising sensor arrays, wherein the body panels are arranged on any one of the front, rear, left and right sides, vehicle underfloor or vehicle roof.

In embodiments, the vehicle may comprise a vehicle body panel comprising ultrasonic arrays directed to emit or receive ultrasonic waves over an arc around the perimeter of the vehicle of substantially 360 degrees, 270 degrees, 180 degrees, 90 degrees or 45 degrees, or an arc in any range formed from any of these preceding values. In embodiments, the vehicle may comprise a plurality of vehicle body panels each comprising sensor arrays, thus, the vehicle may be capable of emitting or receiving ultrasonic waves in a plurality of arcs.

In embodiments, the vehicle may comprise a vehicle body panel comprising a sensor array, wherein the ultrasonic elements of the sensor array are directed horizontally outwards, and/or outwards and downwards, and/or outward and upwards.

In embodiments, the vehicle may comprise a control system 505 for controlling the or each array of ultrasonic elements.

Referring to figure 6A, a method 601 of making a vehicle body member with an array of ultrasonic transducers is shown. The method comprises the step of applying a conductive pathway onto the surface of a vehicle body panel at 602. Wherein the vehicle body panel has been shaped prior to applying the conductive pathway. Thus, the vehicle body panel functions as a substrate onto which the conductive pathway is applied. The conductive pathway is applied to the substrate to comprise one or more contact elements. A piezo electric film is then applied to the substrate over the printed contact elements at 603.

Referring to figure 6B, a method 604 of making a vehicle body member with an integrated array of ultrasonic transducers is shown. The method comprises the step 602 of applying a conductive pathway onto the surface of a substrate, wherein the substrate comprises a preform. A piezo electric film is then applied to the substrate over the printed contact elements at 603. After applying the conductive pathway and/or the piezoelectric film, the preform may then be shaped 605 into the vehicle body member.

Shaping of the preform may comprise applying any applicable moulding method, non-limiting examples comprise: vacuum forming, compression moulding, thermoforming, rotational moulding or blow moulding.

In embodiments, the conductive pathways may be applied to a substrate in a precursor arrangement. The precursor arrangement may be such that during shaping of the preform, the precursor arrangement is transformed to the desired shape of the on the vehicle body member. The shape of the precursor arrangement may be determined based in the movement of the preform during shaping.

Referring to figure 6C, a method 606 of making a vehicle body member with an integrated array of ultrasonic transducers is shown. The method comprises the step 602 of applying a conductive pathway onto the surface of a substrate, wherein the substrate comprises a material arranged to be attached to a vehicle body member.

The method comprises the step 603 of applying a piezo electric film to the substrate and/or conductive pathway. The method also comprises attaching the substrate to the vehicle body member at 604. The piezo electric film may be applied to the substrate before or after the substrate is attached to the vehicle body member. The substrate may also be applied to a vehicle body member that is in-situ on a vehicle.

The substrate may comprise any sheet material, non-limiting examples comprise: a polymer sheet, a fibre reinforced polymer sheet and sheet metal. In embodiments, the substrate may be an electrically insulating sheet material. In embodiments, the substrate may comprise an adhesive layer.

The substrate may be attached by use of an adhesive, welding, thermoforming, mechanical fasteners or any other known suitable attachment method.

In embodiments, the step of applying the conductive pathway to the substrate may comprise any one of printing the conductive pathway using mechanical printing, inkjet printing or screen printing, vapor deposition, spray deposition, spluttering, etching, precipitating, or laser sintering/deposition. In embodiments, the conductive pathways may be applied to the substrate by screen printing a metallic ink to the shape of the conductive pathways.

The piezoelectric film may be attached by an adhesive, by solvent deposition, spray deposition, melt forming, or casting, amongst others.

In embodiments, vehicle body panel may comprise any of EMI shielding, protective laminates, coatings, and interconnects for the conductive pathways.

In alternative embodiments, the piezo electric film may be applied first to the substrate, and a conductive pathway placed thereon. In embodiments, a body panel as shown in figure 4 may be produced by first depositing a first conductive pathway on to a substrate, applying a piezo electric film, then applying a second conductive pathway.

With reference to Figure 7, there is illustrated a simplified example of the control system 505 such as may be adapted to implement a method of controlling the or each array of ultrasonic elements described above. The control system 505 comprises one or more controllers 710 and is configured to generate and output an electrical signal 712 along at least one conductive pathway, for example conductive pathways 104a, 104b, to the array of ultrasonic elements, receive an electrical signal 714 along the at least one conductive pathway from the array of ultrasonic elements, and process the received electrical signal, for example by way of comparison with the electrical signal 712 output, to determine certain characteristics of the environment towards which the array of ultrasonic elements is directed.

It is to be understood that the or each controller 710 can comprise a control unit or computational device having one or more electronic processors (e.g., a microprocessor, a microcontroller, an application specific integrated circuit (ASIC), etc.), and may comprise a single control unit or computational device, or alternatively different functions of the or each controller 710 may be embodied in, or hosted in, different control units or computational devices. As used herein, the term "controller," "control unit," or "computational device" will be understood to include a single controller, control unit, or computational device, and a plurality of controllers, control units, or computational devices collectively operating to provide the required control functionality. A set of instructions could be provided which, when executed, cause the controller 710 to implement the control techniques described herein (including some or all of the functionality required for the method described herein). The set of instructions could be embedded in said one or more electronic processors of the controller 710; or alternatively, the set of instructions could be provided as software to be executed in the controller 710. A first controller or control unit may be implemented in software run on one or more processors. One or more other controllers or control units may be implemented in software run on one or more processors, optionally the same one or more processors as the first controller or control unit. Other arrangements are also useful.

In the example illustrated in Figure 7, the or each controller 710 comprises at least one electronic processor 720 having one or more electrical input(s) 722 for receiving one or more electrical signal(s) received from the array(s) of ultrasonic elements, and one or more electrical output(s) 724 for outputting one or more output signal(s) to the array(s) of ultrasonic elements. The or each controller 710 further comprises at least one memory device 730 electrically coupled to the at least one electronic processor 720 and having instructions 740 stored therein. The at least one electronic processor 720 is configured to access the at least one memory device 730 and execute the instructions 740 thereon so as to generate and output the electrical signal 712, receive the electrical signal 714, and process the received electrical signal to determine the characteristics of the environment towards which the array of ultrasonic elements is directed.

The, or each, electronic processor 720 may comprise any suitable electronic processor (e.g., a microprocessor, a microcontroller, an ASIC, etc.) that is configured to execute electronic instructions. The, or each, electronic memory device 730 may comprise any suitable memory device and may store a variety of data, information, threshold value(s), lookup tables or other data structures, and/or instructions therein or thereon. In an embodiment, the memory device 730 has information and instructions for software, firmware, programs, algorithms, scripts, applications, etc. stored therein or thereon that may govern all or part of the methodology described herein. The processor, or each, electronic processor 720 may access the memory device 730 and execute and/or use that or those instructions and information to carry out or perform some or all of the functionality and methodology describe herein.

The at least one memory device 730 may comprise a computer-readable storage medium (e.g. a non-transitory or non-transient storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors/computational devices, including, without limitation: a magnetic storage medium (e.g. floppy diskette); optical storage medium (e.g. CD-ROM); magneto optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g. EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information/instructions.

Example controllers 710 have been described comprising at least one electronic processor 720 configured to execute electronic instructions stored within at least one memory device 730, which when executed causes the electronic processor(s) 720 to carry out the method as hereinbefore described. However, it is contemplated that the present invention is not limited to being implemented by way of programmable processing devices, and that at least some of, and in some embodiments all of, the functionality and or method steps of the present invention may equally be implemented by way of non-programmable hardware, such as by way of non-programmable ASIC, Boolean logic circuitry, etc. The vehicle body panel may perform additional functions as well as the purpose referred to herein. For example, the sensor may be used as any one of: apparatus for emitting sounds from a vehicle, a parking sensor; a sensor for determining the depth of a vehicle; a sensor for near zone imaging of a vehicle; as a microphone for detecting external sounds.

The vehicle body panel may perform different functionalities depending on the current state of the vehicle. Non-limiting exemplary vehicle states comprise: where the vehicle is in parking mode, the sensor may be operated as a parking sensor; where the vehicle is off-road, or moving in traffic, it may be operated as a near zone imaging device for controlling speed and/or steering, when the vehicle is in motion, it may be used to emit sounds; and where the vehicle is occupied, it may be used as a microphone or for emitting sounds.

Where the vehicle is in two concurrent states, changing between functionalities may be operated by the controller or vehicle control unit. For example, where a vehicle in in motion, the sensor may be used as a near field sensor, however, when the controller identifies a pedestrian or car in a hazardous position, the controller may operate the sensor to emit a warning sound to the pedestrian, before resuming operation as a near

field sensor.

All of the features disclosed in this specification (comprising any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (comprising any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (comprising any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The claims should not be construed to cover merely the foregoing embodiments, but also any embodiments which fall within the scope of the claims. 1. 2. 3. 4. 5. 6. 7.

Claims

CLAIMSA vehicle body member comprising an array of ultrasonic elements, comprising: a substrate, wherein the substrate is the vehicle body member or is arranged to be attached to a vehicle body member; at least one electrically conductive pathway comprising one or more contact elements, the conductive pathway attached to a surface of the substrate; at least one piezo electric film in electrical contact with the one or more contact elements to form one or more ultrasonic elements of the array of ultrasonic elements.
A vehicle body member according to claim 1, wherein the substrate or vehicle body member comprises a surface comprising one or more cavities.
A vehicle body member according to claim 2, wherein the one or more contact elements are coincident with the one or more cavities.
A vehicle body member according to claim 2 or claim 3, wherein the one or more cavities are configured to reflect an anti-phase wave to the one or more ultrasonic elements, when the ultrasonic elements are operated at an operation frequency.
A vehicle body member according to any preceding claim, wherein at least a portion of the conductive pathway is arranged as a digitated structure on the surface of the substrate.
A vehicle body member according to any preceding claim, wherein at least two portions of the conductive pathway are arranged as an interdigitated structure.
A vehicle body member according to any preceding claim, wherein the conductive pathway comprises at least two portions separated by the piezo electric film.
8. A vehicle body member according to any preceding claim, wherein the vehicle body member comprises at least one layer of elastomeric paint.
9. A vehicle body member according to any preceding claim, wherein the piezo electric film comprises a single continuous film.
10. A vehicle body member according to any preceding claim, comprising at least 10, 50, 100, 200 or 500 ultrasonic elements.
11. A vehicle body member according to any preceding claim, wherein the vehicle body member is a front or rear vehicle bumper.
12. A vehicle comprising a vehicle body member according to any preceding claim. 15
13. A method of making a vehicle body member with an array of ultrasonic elements, the method comprising: providing at least one electrically conductive pathway on a surface of a substrate, the conductive pathway comprising one or more contact elements; applying a piezoelectric film to form an electrical contact with the one or more contact elements; wherein: the substrate is shaped as the vehicle body member before the at least one electrically conductive pathway is provided on the surface of the substrate, or the substrate is attached to the surface of a vehicle body member after the at least one electrically conductive pathway is provided on the surface of the substrate, or the substrate is a preform that is shaped as the vehicle body member after the at least one electrically conductive pathway is provided on the surface of the substrate.
14. A method according to claim 13, wherein the at least on electrically conductive pathway is printed onto the surface of the substrate.
15. A method according to claim 13 or claim 4 comprising forming one or more cavities on a surface of the vehicle body member or substrate.
16. A method according to claim 15, wherein providing a conductive pathway on the surface of the substrate comprises providing the conductive pathway so that the one or more of the contact elements are coincident with the one or more cavities.
17. A method according to any of claims 13 to 16, comprising applying elastomeric paint to one or more of: the piezoelectric film, the conductive pathway or the substrate.
18. A method according to any of claims 13 to 17, wherein providing a conductive pathway on the surface of the substrate comprises providing at least a portion of the conductive pathway as a digitated structure.
19. A method according to claim 18, comprising providing a second conductive pathway or a second portion of a conductive pathway as a digitated structure, interdigitated with a first digitated structure.
20. A method according to any of claims 13 to 19, comprising providing a second conductive pathway or a second portion of a conductive pathway onto the piezo electric film.
21. A method according to any of claims 13 to 20, wherein the substrate is shaped as a vehicle bumper or the substrate is applied to a member shaped as a vehicle bumper.