Radar Cover Bright Layer Design for Electromagnetic Transmission
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Solution Overview
Problem
The manufacturing process of radar covers with bright layers that can transmit electromagnetic waves is complicated due to the need for separate processes to form base coat, bright, and top coat layers.
Innovation Solution
A radar cover configuration where a discontinuous metal bright layer is formed directly on a base portion with openings, and a transparent top coat layer is applied in close contact with the base portion through these openings, eliminating the need for a base coat layer and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a base coat layer is formed between the base portion and the bright layer to ensure adhesion, then the adhesion strength is improved, but the manufacturing process becomes more complicated and the number of processing steps increases
Solution Approach 1:
The invention extracts and removes the base coat layer from the multi-layer structure, reducing it from three layers (base coat, bright layer, top coat) to two layers (bright layer, top coat). The bright layer is formed directly on the base portion, eliminating the need for the base coat layer while maintaining adhesion through direct formation on the base portion surface.
Solution Approach 2:
The invention merges the functions of the base coat layer and the bright layer into a single bright layer structure. The bright layer serves both as the adhesive base for the top coat and as the electromagnetic wave transmitting layer with metallic brilliance, combining multiple functions that were previously separated into different layers.
2Strength
If a base coat layer is formed separately from the bright layer to ensure proper adhesion, then the adhesion is improved, but the manufacturing time and processing steps increase
Solution Approach 1:
The formation processes of the base coat layer and bright layer are merged into a single process step. The bright layer is formed directly on the base portion in one continuous operation, eliminating the separate base coat formation step and reducing total manufacturing time while maintaining adhesion quality.
Solution Approach 2:
The surface of the base portion is prepared in advance to enable direct formation of the bright layer with adequate adhesion. By pre-treating the base portion surface appropriately, the invention eliminates the need for an intermediate base coat layer, allowing the bright layer to be formed directly with sufficient bonding strength.
3Illumination intensity
If plating treatment is applied to provide metallic brilliance, then the luxuriousness and texture are improved, but the transmission of electromagnetic waves is blocked
Solution Approach 1:
The bright layer is designed with a porous or discontinuous structure containing numerous fine holes, allowing electromagnetic waves to pass through while maintaining the metallic brilliance appearance. This porous structure enables simultaneous achievement of aesthetic appearance and electromagnetic wave transmission functionality.
Solution Approach 2:
The bright layer has non-uniform local properties: in some regions it provides metallic brilliance through metal material, while in the holes it allows electromagnetic wave transmission. This local variation in material properties enables the layer to simultaneously fulfill both aesthetic and functional requirements.
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 configuration allows for the transmission of electromagnetic waves while simplifying the manufacturing process by eliminating the need for a base coat layer, maintaining adhesion and tensile strength comparable to conventional designs.
Implementation Method 1
a bright layer which is formed directly on a surface of the base portion and is a discontinuous metal layer having openings penetrating therethrough in a layer thickness direction
Implementation Method 2
parts of the top coat layer being directly in close contact with the base portion through the openings of the bright layer
Data Source
Figure 1~2
Figure 3A~3B
Figure 4(a)~4(e)
AI summary
A radar cover (10) for covering a radar unit (R) which detects a situation around a vehicle, includes: a base portion (12a) which serves as a frame; a bright layer (12b) which is formed on a surface of the base portion and is a discontinuous metal layer having openings penetrating therethrough in a layer thickness direction; and a transparent top coat layer (12b) formed on a surface of the bright layer, parts of the top coat layer being in close contact with the base portion through the openings of the bright layer.