Vehicle Cruise Control Sensor Cover with Indium NCVM Coating
Solution Overview
Problem
Conventional vehicle cruise control sensor-covers impede the aesthetic design of vehicle grills and hinder the continuity of grill designs, while also being non-abrasion and weather-resistant, and do not ensure electromagnetic transparency.
Innovation Solution
A vehicle cruise control sensor-cover with a metallic color and material, achieved through a non-conductive vacuum metallization method using indium or indium-containing alloys on a bottom cover member, combined with a transparent top cover member featuring a hard coating layer and selective laser etching, ensuring electromagnetic transparency and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cruise control sensor-cover is positioned in the grill of a vehicle, then the sensor is protected, but the continuity of grill design is impeded and aesthetic sense is hindered
Solution Approach 1:
The sensor cover is designed with differentiated local qualities: the main body maintains a uniform color matching the grill, while only the logo area receives a metallic finish. This localized differentiation allows the cover to blend seamlessly with the grill design while still providing sensor protection and enabling logo identification.
2Shape
If a metallic finish is applied to the sensor-cover, then aesthetic appeal is enhanced, but electromagnetic transparency is compromised
Solution Approach 1:
The metallic finish is applied locally only to the logo area rather than the entire sensor cover. This localized application provides the desired aesthetic appeal and brand identification while minimizing interference with the electromagnetic transparency required for sensor operation.
Solution Approach 2:
The sensor cover uses a composite structure combining a transparent or translucent base material with a metallic coating layer. This composite approach allows the cover to exhibit metallic aesthetic properties while maintaining sufficient electromagnetic transparency for the sensor to function effectively.
3Shape
If a three-dimensional emblem structure is created separately and assembled, then the three-dimensional effect is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
The logo and the sensor cover body are merged into a single integrated component rather than being separate parts. The logo is formed as an integral part of the cover through molding or direct metallic deposition, eliminating the need for separate assembly operations and reducing manufacturing complexity while maintaining the three-dimensional visual effect.
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
The solution provides a sensor-cover that is abrasion-resistant, weather-resistant, and maintains electromagnetic transparency, while enhancing the three-dimensional effect of logos and reducing manufacturing defects and costs, thus improving the aesthetic appeal and functionality of vehicle designs.
Implementation Method 1
indium or an indium-containing alloy is deposited, by using a non-conductive vacuum metallization (NCVM) method, on a front surface of a bottom cover body
Implementation Method 2
a laser etching process is partially selectively performed only on the logo or the outer edge on the back surface of the top cover body to partially form an etched surface
Data Source
AI summary
The present disclosure provides a vehicle cruise control sensor-cover and a method of manufacturing the vehicle cruise control sensor-cover, the vehicle cruise control sensor-cover including a bottom cover member wherein indium or an indium-containing alloy is deposited, by using a non-conductive vacuum metallization (NCVM) method, on a front surface of a bottom cover body having a logo and an outer frame protruding three-dimensionally and a top cover body including a transparent material and having a back surface formed in a shape corresponding to the front surface of the bottom cover member, wherein the top cover member is assembled integrally with the front surface of the bottom cover member, and a laser etching process is partially selectively performed only on the logo or the outer edge on the back surface of the top cover body to partially form an etched surface.