Integrated Molding and Sputtering for Electromagnetic Wave Transmission
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Solution Overview
Problem
Conventional methods for manufacturing film-formed molded products with electromagnetic wave transmission capabilities are complex and costly, requiring large-scale equipment and processes that are prone to moisture absorption, static electricity, and dust adhesion, leading to reduced yield and increased manufacturing costs.
Innovation Solution
A method where a non-conductive molded product is formed and coated with a metal film in the same mold, allowing for integrated molding and film-forming processes that prevent moisture absorption and dust adhesion, and create cracks in the metal coating for electromagnetic wave transmission, simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the molded product is transported from the molding machine to the film-forming device, then the metal coating film can be formed, but the molded product absorbs moisture, becomes electrically charged, and dust adheres to it, reducing yield
Solution Approach 1:
The patent combines the molding machine and film-forming device into an integrated system where the film formation process is performed within the molding machine's mold cavity. This eliminates the need to transport the molded product between separate devices, preventing moisture absorption, static electricity generation, and dust adhesion that occur during transportation.
Solution Approach 2:
The mold is divided into functional regions: a molding portion for forming the molded product and a film-forming portion for depositing the metal coating film. This segmentation allows both processes to occur simultaneously in the same equipment without interfering with each other, while maintaining a controlled environment that prevents contamination.
2Reliability
If cleaning equipment and static elimination devices are added to prevent moisture and dust issues, then yield improves, but equipment complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the need for separate cleaning equipment and static elimination devices by performing both molding and film formation within the same controlled environment. The integrated system inherently prevents contamination issues without requiring additional complex equipment.
3Manufacturing precision
If the metal coating film is formed on the heated molded product by sputtering and then cracks are formed by cooling, then electromagnetic wave transmission is achieved, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent merges the molding and film-forming processes into a single integrated operation where the metal coating film is deposited on the molded product while it is still in the mold cavity. The subsequent cracking process to create electromagnetic wave transmission is also integrated into the same equipment system, eliminating the need for separate heating, cooling, and cracking equipment.
Solution Approach 2:
The invention utilizes parameter changes within the integrated system - specifically temperature changes and pressure changes - to achieve both the metal coating film formation and the subsequent cracking process. These parameter changes are controlled within the same equipment environment, simplifying the overall manufacturing process.
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 miniaturizes equipment, reduces manufacturing costs, and enhances the electromagnetic wave transmission performance while maintaining the decorative metallic luster, allowing for more design flexibility in vehicle components like emblems and radome applications.
Implementation Method 1
the metal coating film is formed on the heated molded product by a sputtering method
Implementation Method 2
a process of keeping the temperature of the molded product or raising (heating) the temperature of the molded product
Implementation Method 3
the cracks are formed by cooling the molded product
Data Source
AI summary
The present invention achieves cost reduction by simplifying the manufacturing process for a film-formed molded product provided with a metal coating film capable of transmitting electromagnetic waves therethrough. This method for manufacturing a film-formed molded product which includes a molded product and a metal coating film covering the molded product comprises: forming the molded product between a movable mold and a fixed mold; and then forming the metal coating film which covers the molded product by a film-forming part of a second mold without taking the molded product out from between the movable mold and the fixed mold. The metal coating film is capable of transmitting electromagnetic waves therethrough as a result of generation of cracks after being formed.