Vehicle Cladding Penetration Section Plastic Foil Dampening
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Solution Overview
Problem
The existing external cladding components of vehicles, typically made of thermoplastics, dampen electromagnetic waves used by radar sensors, leading to reduced monitoring range, and adjusting the wall thickness to optimize sensor performance is costly and affects the component's quality.
Innovation Solution
A method to adjust the dampening degree of electromagnetic waves by applying a plastic foil within the penetration section of the external cladding component, which is easy, cost-efficient, and minimally visible, using a combination of lacquers and a primer to enhance adhesion and protection, allowing for precise adjustment of the component's thickness without altering the entire cladding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wall thickness of the external cladding component is increased to reduce dampening of electromagnetic waves, then the monitoring range of radar sensors is improved, but the weight and cost of the component increase
Solution Approach 1:
The patent applies a plastic foil specifically in the penetration section where electromagnetic waves pass through, rather than increasing the wall thickness of the entire external cladding component. This localized modification reduces dampening in the critical area while maintaining the original weight-optimized thickness in non-critical areas, thus improving monitoring range without proportionally increasing weight.
Solution Approach 2:
The external cladding component is divided into different sections: the penetration section where the plastic foil is applied to reduce dampening, and other sections that maintain the original wall thickness optimized for weight and stiffness. This segmentation allows targeted modification only where necessary for sensor performance.
2Reliability
If the wall thickness is increased by applying further material to correct dampening, then the monitoring range is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent uses a plastic foil as a thin film applied to the penetration section of the external cladding component. This approach is simpler than traditional methods that would require complex injection molding tools or multi-layer co-molding processes. The foil can be applied using standard adhesive bonding techniques, significantly reducing manufacturing complexity while achieving the desired dampening correction.
3Reliability
If the wall thickness is decreased to adjust dampening, then the monitoring range is improved, but the surface quality is negatively affected by sink marks
Solution Approach 1:
Instead of removing material (which would cause sink marks), the patent applies a plastic foil with predetermined thickness to compensate for excessive dampening. This preliminary addition of material counteracts the dampening effect without requiring material removal, thus avoiding surface quality degradation from sink marks while achieving the desired electromagnetic wave penetration characteristics.
4Reliability
If the wall thickness of the entire external cladding component is changed to optimize sensor performance, then the dampening degree is improved, but the weight and stiffness optimization is compromised
Solution Approach 1:
The patent modifies only the penetration section where electromagnetic waves pass through by applying a plastic foil, while maintaining the original wall thickness in other sections. This allows optimization of the dampening degree in the critical penetration area without compromising the overall weight and stiffness optimization of the entire external cladding component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces dampening of electromagnetic waves in the 50-200 GHz range, enhancing the monitoring range of radar sensors while maintaining the component's design integrity and reducing material costs and weight.
Implementation Method 1
Depending on the thickness, in particular the wall thickness of the external cladding component the electromagnetic waves are more or less dampened. The more the waves are dampened the smaller is the range by which the sensors can monitor the surroundings of the vehicle.
Implementation Method 2
The top lacquer (20) is embodied as a clear lacquer (22). Moreover, the plastic foil (30) is embodied as being applied to the top lacquer (20) by means of an adhesive layer (32).
Data Source
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Figure 5
AI summary
The present disclosure relates to an external cladding component (10) of a vehicle (11), comprising a penetration section (28) that is permeable to electromagnetic waves (λ) in the range between 50 and 200 GHz, the penetration section (28) comprising a plastic body (12) having a first surface (14) and a second surface (16),a basic lacquer (18) applied to the first surface (14), a top lacquer (20) applied on the basic lacquer (18), and a plastic foil (30). Moreover the present disclosure relates to a vehicle (11) comprising such an external cladding component (10) and to a method for manufacturing such an external cladding component (10).