Radar Emblem Laminated Structure With Fitting Joints and Low Attenuation
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Solution Overview
Problem
The existing laminated structures used in automobile emblems for millimeter wave radar systems are prone to damage during the insert molding process, leading to deterioration of the metal layer and impaired appearance, which increases manufacturing costs and reduces productivity.
Innovation Solution
A laminated structure comprising an outer member with a concave portion, a metal layer, and an inner member with a convex portion that fits into the concave portion to form a fitting portion, where the metal layer includes a silver particle layer with a sea-island structure, reducing transmission attenuation and maintaining the appearance without insert molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If insert molding is used to eliminate gaps between members, then transmission attenuation is reduced, but the metal layer is damaged and appearance deteriorates
Solution Approach 1:
The invention divides the emblem into multiple members (first member, second member, third member) that are assembled together without insert molding. The concave-convex fitting portions allow the members to be joined while eliminating gaps that would cause transmission attenuation, yet avoiding the high temperature and pressure of insert molding that damages the metal layer.
Solution Approach 2:
The invention combines multiple members (first member with metal layer, second member, third member) into a single emblem structure through concave-convex fitting. This merging approach eliminates gaps between members to reduce transmission attenuation while using a gentle assembly process that preserves the metal layer appearance.
2Manufacturing precision
If a protective film is provided on the inner member or outer member to prevent metal layer damage, then appearance is maintained, but manufacturing costs increase and productivity decreases
Solution Approach 1:
The invention extracts the protective function from a separate protective film and integrates it into the structural design of the members themselves. The first member's concave portion and the second member's convex portion create a protective fitting structure that prevents metal layer damage during assembly without requiring an additional protective film layer.
3Adaptability or versatility
If multiple members are laminated to form an emblem, then design flexibility is improved, but gaps between members cause transmission attenuation
Solution Approach 1:
The invention applies local quality by creating concave and convex portions at specific locations where members join. This localized structural feature ensures that gaps are eliminated at the interfaces between members, reducing transmission attenuation, while the rest of the members maintain their individual design characteristics and flexibility.
Data Source
AI summary
A laminated structure includes, in the following order: an outer member having a concave portion; a metal layer; and an inner member having a convex portion that is fitted with the concave portion to form a fitting portion.