Electromagnetic-wave Transmitting Cover with Adhesive Layer
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Solution Overview
Problem
Existing electromagnetic-wave transmitting covers for vehicle radars are limited in design expression and performance, as they cannot effectively extend the sensing range and angle due to interference from the front grille's metal components and suffer from heat-induced deformation during the molding process.
Innovation Solution
An electromagnetic-wave transmitting cover with a base material and a light-transmitting base material separated by an adhesive layer, where the design layer is sandwiched between them, allowing for a closer interval of 0.12 mm or less and minimizing phase deviation, enabling expanded design expression and improved radar performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If members are separated by a gap to reduce electromagnetic wave loss, then electromagnetic wave transmission is improved, but the design layer cannot be formed in the peripheral fixing area
Solution Approach 1:
An adhesive layer is introduced as an intermediary substance between the front-side member and rear-side member, replacing the traditional air gap. This adhesive layer has electromagnetic wave transmission properties similar to air but allows the design layer to extend continuously to the outer peripheral portion, enabling full-surface design expression while maintaining radar wave transmission capability.
2Reliability
If members are integrally bonded at the outer peripheral portion for water-proofing, then water-proof property is improved, but the design layer is limited and cannot be formed in the bonding area
Solution Approach 1:
The adhesive layer serves as a mediator that provides both water-proof bonding and electromagnetic wave transmission. It bonds the front-side and rear-side members together for water-proofing while allowing the design layer to extend to and be formed in the outer peripheral portion, eliminating the need to exclude the design layer from the bonding area.
3Ease of manufacture
If insert molding is used to fix members, then manufacturing is simplified, but heat causes deformation of the design layer
Solution Approach 1:
The adhesive layer is designed with specific material parameters (low viscosity, appropriate curing temperature) that allow it to be applied at low temperatures and then cured without generating excessive heat. This parameter optimization enables the design layer to be formed up to the outer peripheral portion without heat-induced deformation, while still providing effective bonding.
4Reliability
If the interval between base material and light-transmitting base material is reduced to minimize phase deviation, then radar performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The adhesive layer is formulated with specific physical parameters (thickness, dielectric constant, viscosity) that enable it to maintain a controlled interval of 0.12 mm or less between the base material and light-transmitting base material. This parameter control minimizes phase deviation of the radar wave while being achievable through standard manufacturing processes.
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 achieves range extension and angle widening of the sensing radar while maintaining excellent design properties, suppressing phase deviation and heat-induced damage, thus enhancing the radar's functionality and aesthetic appeal.
Implementation Method 1
an adhesive layer is formed on an entire surface between the base material and the light-transmitting base material
Implementation Method 2
a deviation in angle of the electromagnetic wave when the electromagnetic wave is transmitted through the electromagnetic-wave transmitting cover is 0.3° or less
Data Source
AI summary
To provide an electromagnetic-wave transmitting cover which can achieve range extension and angle widening of a sensing radar and is excellent in design property. An electromagnetic-wave transmitting cover of the invention includes a base material made of an electromagnetic-wave-transmissive material, a light-transmitting base material formed on a surface of the base material and made of a light-transmissive material, and a design layer disposed between the base material and the light-transmitting base material, the electromagnetic-wave transmitting cover transmitting an electromagnetic wave, the electromagnetic-wave transmitting cover has an electromagnetic-wave transmitting area which transmits the electromagnetic wave, the base material and the light-transmitting base material in the electromagnetic-wave transmitting area has an interval of 0.12 mm or less, an adhesive layer is formed on an entire surface between the base materials, and a deviation in angle when the electromagnetic wave is transmitted is 0.3° or less.