Decorative PVD Radome Coating With Low RF Attenuation
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Solution Overview
Problem
Existing methods for creating decorative radomes with metallic appearances are complex, costly, and inefficient, often requiring multiple layers and adhesives, which can lead to radio wave attenuation, delamination, and environmental hazards, while failing to provide transparent, durable, and visually appealing designs suitable for automotive applications.
Innovation Solution
A method involving physical vapor deposition (PVD) of a thin, radio-transmissive decorative coating on a substrate, followed by overmolding to create a unified, durable, and visually appealing radome with integrated backlighting capabilities, using metalloids like germanium to minimize radio wave attenuation and enhance resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional liquid solant-based anodizing or plasma spraying is used to apply decorative coatings, then the coating can be applied to the substrate, but the process is time-consuming, costly, and environmentally harmful due to toxic solants and heavy metals
Solution Approach 1:
The patent changes the fundamental parameters of the coating process by transitioning from liquid solant-based methods to PVD (physical vapor deposition) technology. This involves changing the deposition mechanism from chemical/liquid-phase to physical vapor-phase deposition, eliminating toxic solants and heavy metals while maintaining decorative functionality. The PVD process uses vacuum evaporation or sputtering to deposit metallic or ceramic coatings, fundamentally altering the process parameters to achieve environmental compatibility.
Solution Approach 2:
The patent replaces the chemical/mechanical coating processes (liquid solant application, anodizing, plasma spraying) with a physical vapor deposition process. Instead of using liquid chemicals that require drying and curing, or plasma spraying that uses high-velocity particle injection, the invention uses controlled vapor condensation in a vacuum environment to deposit coatings, substituting one physical mechanism for another more environmentally benign one.
2Object-affected harmful factors
If PVD coating is applied to achieve environmental compatibility and process efficiency, then harmful factors are eliminated, but the coating requires precise control of deposition parameters to achieve desired thickness and uniformity
Solution Approach 1:
The PVD process implements real-time feedback control through quartz crystal microbalance (QCM) sensors that continuously monitor the deposition rate and coating thickness during the vacuum deposition process. This feedback system allows dynamic adjustment of deposition parameters to maintain precise thickness control and uniformity across the substrate surface, addressing the precision challenge inherent in vacuum-based coating methods.
Solution Approach 2:
The patent employs substrate rotation and/or coating target vibration during the PVD deposition process to enhance coating uniformity. By introducing controlled mechanical motion, the system ensures even distribution of deposited material across the substrate surface, preventing localized thickness variations and achieving the desired uniformity without requiring excessively slow deposition rates.
3Adaptability or versatility
If decorative patterns are created through traditional methods, then the design can be applied, but the process requires multiple steps and additional materials
Solution Approach 1:
The patent combines the coating deposition and pattern creation processes into a single integrated PVD operation. By using programmable mask systems or direct digital laser writing during the vacuum deposition process, the invention merges what would traditionally be separate coating application and pattern printing steps into one unified process, reducing manufacturing complexity while maintaining design versatility.
Solution Approach 2:
The system performs preliminary digital design and pattern programming before the actual deposition begins. The decorative patterns are pre-programmed into the PVD system's control software, allowing the deposition process itself to directly create the final patterned coating without requiring subsequent masking, printing, or finishing steps. This preliminary digital preparation enables complex designs to be achieved through a single deposition cycle.
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 method enables cost-effective, high-throughput production of radomes with minimal radio wave attenuation, improved durability, and enhanced visual appeal, suitable for various automotive applications, including 360° radar coverage and decorative components.
Implementation Method 1
applying a PVD coating by magnetron sputtering to the substrate
Implementation Method 2
laser etching one or more of a pattern or a graphic into the PVD coating; wherein the PVD coating is laser etched
Data Source
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Figure 2a~2c
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AI summary
A decorative radome including a radio-transmissive substrate having a first surface on a first side and a second surface on a second side; and a first surface radio-transmissive decorative coating; methods of manufacturing a PVD coated system include applying a hard coating to the substrate; applying a PVD coating by magnetron sputtering to the substrate; and laser etching one or more of a pattern or a graphic into the PVD coating; and A decorative PVD coated item, comprising:a substrate; a hard coating applied to the substrate; a PVD coating provided on the hard coating and the substrate, wherein the PVD coating is laser etched with one or more of a pattern or a graphic so that the PVD coating is at least partially removed and the pattern or the graphic is revealed as a result of the contrast between the substrate and the PVD coating.