Carbon nanotubes offer unique properties, which are leading to intriguing opportunities. One potential market is automotive, where carbon nanotubes are particularly ideal for Light Detection and Ranging (LiDAR) systems.

LiDAR systems are key to autonomous driving, as they detect objects and measure distances and then provide 3D mapping. If the LiDAR system is blocked by wintry conditions or fog, the 3D mapping loses accuracy.

At CES 2023, Canatu and Covestro demonstrated their joint LiDAR heater system,  bringing together expertise in flexible transparent film heaters, thermoplastic polymers and film insert molding processing, at the Canatu booth. The LiDAR cover lens offers heating capabilities, which deice the lens.

“By combining Covestro’s highly developed expertise in optical-grade polymers with Canatu’s unique CNT film heater technology, we have jointly developed a functionalized LIDAR cover lens combining high optical properties and effective heating. Together, we are enabling ADAS in any weather without compromising on safety, performance, and functionality,” said Tero Tolonen, chief product officer of Canatu, in announcing the project.

Mari Makkonen, VP, marketing & communications for Canatu Oy, said that Canatu and Covestro have collaborated on the LiDAR deicing project for about a year.

“The new demonstrator features Canatu CNT film heater on Covestro Makrofol DE or Makrofol ST polycarbonate (PC) film, integrated by means of film insert molding (FIM) technology using Covestro Makrolon AG or Makrolon AX PC resin on the backside of the foil,” said Makkonen. “Covestro delivers their optical-grade polycarbonate film substrate, and Canatu creates their transparent film heater on top of it.”

Makkonen pointed out that Canatu’s CNT film heater keeps LiDAR clear of fog, snow and ice, enabling autonomous driving in any weather. It is wire-free, thus allowing clear vision for the laser to map the surroundings.

“Key benefits include high transmittance in IR,” added Makkonen. “It is wire-free without any temperature gradient of picture distortion, offers fast, even and power-efficient heating, and can be customized to desired optical, heating and design requirements across a range of input voltages.”

Once Canatu creates the transparent film heaters on top of the substrate, it undergoes high pressure forming or thermoforming.

“During film insert molding, a plastic film is shaped via high-pressure forming (HPF) or thermoforming (TF), trimmed, and the resulting pre-formed insert is then placed in an injection mould, where it is back-injected with a thermoplastic,” Makkonen said.

“The FIM process eliminates separate steps, such as coating or painting, that otherwise are required to subsequently decorate or functionalize components. This results in considerable savings in terms of manufacturing costs, time and machine investments. It also creates more flexibility in the production of complex, functional parts and results in better reliability.

“The 3D-formed heater foil is integrated via FIM using Makrolon resin into the LiDAR front module part,” Makkonen added. “Headlights are also typically created by FIM process, and Canatu film heaters can also be implemented on headlamps via FIM, providing a robust and reliable structure.”

The CNT film heater technology is currently targeted for the automotive segment. “At Canatu, we are focused on automotive LiDAR, camera and headlights with our CNT film heater products,” Makkonen said.

Makkonen noted that Canatu has received very positive market feedback from Tier 1 and automotive OEM customers.

“Canatu is able to provide a totally unique solution for optically demanding applications with the most advanced transparent heater for LiDARs and cameras having passed relevant environmental requirements,” Makkonen concluded.