Object sensor including deposited heater

Abstract

An illustrative example method of making a sensor device including a cover covering at least one of an emitter and a detector includes establishing a heater on the cover by depositing a fluid comprising an electrically conductive material onto a portion of the cover and curing the deposited electrically conductive material.

We claim: 
     
         1 . A method of making a sensor device including a cover covering at least one of an emitter and a detector, the method comprising
 establishing a heater on the cover by   depositing a fluid comprising an electrically conductive material onto a portion of the cover and   curing the deposited electrically conductive material.   
     
     
         2 . The method of  claim 1 , wherein the cover has an interior surface facing the at least one of the emitter and detector and the method comprises depositing the fluid comprising the electrically conductive material onto the interior surface. 
     
     
         3 . The method of  claim 1 , wherein the depositing comprises screen printing. 
     
     
         4 . The method of  claim 1 , wherein the depositing comprises robotically controlling a flow of the fluid and a pattern of the fluid on the portion of the cover. 
     
     
         5 . The method of  claim 1 , wherein
 the cover comprises a plurality of layers; and   the portion of the cover comprises one of the layers.   
     
     
         6 . The method of  claim 5 , wherein
 one of the layers comprises glass or polycarbonate;   another one of the layers comprises a thin film substrate; and   the method comprises depositing the fluid onto the thin film substrate and adhesively securing the thin film substrate to the one of the layers.   
     
     
         7 . The method of  claim 5 , wherein
 the plurality of layers comprises two layers that comprise glass or polycarbonate;   the method comprises
 depositing the fluid onto a surface of one of the two layers, 
 positioning the surface of the one of the two layers to face toward another of the two layers, and 
 laminating the two layers together with the heater between the two layers. 
   
     
     
         8 . The method of  claim 1 , wherein the curing comprises heating the electrically conductive material. 
     
     
         9 . The method of  claim 8 , wherein
 the cover comprises glass; and   the heating comprises heating the cover and the electrically conductive material in a firing furnace.   
     
     
         10 . The method of  claim 1 , comprising forming at least one electrically conductive connector pad on the cover by depositing some of the fluid comprising the electrically conductive material onto the cover in a pad configuration. 
     
     
         11 . The method of  claim 10 , comprising establishing the heater and forming the at least one connector pad simultaneously. 
     
     
         12 . A sensor device, comprising:
 an emitter configured to emit radiation;   a detector configured to detect radiation reflected off an object;   a cover covering at least one of the emitter and the detector, the cover allowing the radiation to pass through the cover; and   a heater comprising at least one conductor formed onto a portion of the cover from a fluid comprising an electrically conductive material that was deposited onto the portion of the cover and cured.   
     
     
         13 . The sensor device of  claim 12 , wherein
 the cover has an interior surface facing the at least one of the emitter and the detector; and   the portion of the cover including the heater is on the interior surface.   
     
     
         14 . The sensor device of  claim 12 , wherein the heater comprises a wire-like trace comprising the electrically conductive material. 
     
     
         15 . The sensor device of  claim 12 , wherein the electrically conductive material comprises silver. 
     
     
         16 . The sensor device of  claim 12 , wherein
 the heater comprises at least one electrically conductive connector pad;   the at least one connector pad is made of the electrically conductive material; and   the electrically conductive material of the at least one connector pad is deposited in fluid form onto the cover and cured.   
     
     
         17 . The sensor device of  claim 16 , comprising at least one conductive wire having an end soldered to the at least one connector pad. 
     
     
         18 . The sensor device of  claim 16 , wherein
 the electrically conductive material comprises silver; and   the at least one connector pad comprises silver.   
     
     
         19 . The sensor device of  claim 12 , wherein
 the cover comprises a plurality of layers;   one of the layers comprises glass or polycarbonate;   another one of the layers comprises a thin film substrate secured to the one of the layers; and   the portion of the cover comprises the thin film substrate.   
     
     
         20 . The sensor device of  claim 12 , wherein
 the cover comprises a plurality of layers;   the plurality of layers comprises two layers that comprise glass or polycarbonate;   the heater is on one surface of one of the two layers that faces toward another one of the two layers;   the two layers are laminated together; and   the heater is situated between the two layers.