Heatable Automobile Radome Structure With Printed Heating Diaphragm
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Solution Overview
Problem
Existing heatable radome structures for automobiles are complex in design, manufacturing steps, and costly due to their intricate structure and integration processes.
Innovation Solution
A simplified heatable radome structure with a heating diaphragm and cover plates, featuring a bending area portion and conductive mounting holes, integrated through injection molding, and a connector system for enhanced electrical connection and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heating wire is welded to the diaphragm with insert molding and the outer plate is bonded to the diaphragm by sealant, then the heating function is achieved, but the structure becomes integrally complex and manufacturing cost increases
Solution Approach 1:
The patent combines the heating wire, diaphragm, and outer plate into an integrated structure where the heating wire is directly embedded in the diaphragm through insert molding, and the outer plate is injection-molded to directly enclose the heating wire ends, eliminating the need for separate sealant bonding steps and reducing structural complexity while maintaining heating functionality
Solution Approach 2:
The heating wire is pre-welded to the diaphragm and pre-positioned within the outer plate cavity before final injection molding, allowing the heating assembly to be prepared in advance and integrated in one molding operation rather than through multiple sequential assembly steps
2Reliability
If multiple bonding steps with sealant and connectors are used, then electrical connectivity is achieved, but manufacturing steps become complex
Solution Approach 1:
The patent merges the electrical connection function into the injection molding process itself, where the outer plate is molded to directly enclose and electrically connect to the heating wire ends, eliminating separate bonding and connector assembly steps while ensuring reliable electrical connectivity through the integrated molding process
3Reliability
If the heating wire ends are exposed for welding, then electrical connection is achieved, but the structure requires additional shielding components
Solution Approach 1:
The patent combines the shielding function with the outer plate structure itself, where the outer plate is injection-molded to directly enclose the heating wire ends and provide both structural support and electromagnetic shielding in a single component, eliminating the need for separate chromium-plated shielding layers
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 new structure simplifies manufacturing steps, enhances binding force between cover plates, and reduces production costs while maintaining effective heating and electrical connectivity.
Implementation Method 1
the heating wire is provided with a coating, and the heating wire with the coating is printed on the diaphragm according to a set layout
Data Source
AI summary
Provided is a heatable radome structure of an automobile. The structure comprises a diaphragm, a heating wire, and a front cover plate, wherein the heating wire is provided with a coating, and the heating wire with the coating is printed on the diaphragm according to a set layout so as to form an integral heating diaphragm member. The heating diaphragm member comprises a main body portion and a bending area portion, wherein the main body portion is arranged on a front surface of the front cover plate; and the bending area portion is arranged on one side of a rear end of the front cover plate after being bent, a conductive sheet electrically connected to the heating wire is welded to the bending area portion, and a connector is connected to the conductive sheet.