Laser-Weldable Millimeter-Wave Radar Housing Material
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Solution Overview
Problem
Existing millimeter-wave radar housing materials face challenges in achieving low dielectric constant, high strength, high heat resistance, and lightweight properties while being suitable for laser welding, which is essential for reliable connection and sealing.
Innovation Solution
A radar housing material composed of polypropylene, glass fiber, nucleating agent, compatibilizer, organic black colorant, antioxidant, and light stabilizer, processed through an LFT-G method to enhance laser weldability and reduce dielectric constant, with a specific black colorant formulation to improve near-infrared transmittance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If glass fiber reinforced polypropylene is used to achieve low dielectric constant and low cost, then dielectric constant is reduced, but strength and heat resistance deteriorate
Solution Approach 1:
The patent changes the crystallinity parameter of polypropylene from low to high (80-95%) through nucleating agents and controlled cooling, which significantly improves strength and heat resistance while maintaining the low dielectric constant property of glass fiber reinforced polypropylene
Solution Approach 2:
The patent creates a composite material system combining glass fiber reinforced polypropylene with high crystallinity, where the synergistic effect of the composite structure and high crystallinity achieves both low dielectric constant and high strength/heat resistance simultaneously
2Power
If conventional black colorants are added to absorb laser energy for welding, then laser absorption is improved, but near-infrared transmittance deteriorates
Solution Approach 1:
The patent replaces conventional black colorants with specific organic pigments (pyropheophytin a, pyropheophytin b, or their derivatives) that have selective light absorption characteristics - absorbing visible light for laser welding while transmitting near-infrared laser beams for welding processing
3Ease of operation
If screw connection is used for housing assembly, then ease of assembly is improved, but sealing performance and connection reliability deteriorate
Solution Approach 1:
The patent replaces the mechanical screw connection system with a laser welding system that creates molecular-level bonding through laser-induced melting and diffusion welding, achieving superior sealing and connection reliability while maintaining ease of assembly through automated welding 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 material achieves high strength, heat resistance, and low dielectric constant, enabling effective laser welding for secure attachment to mounting surfaces, improving transmission efficiency and sealing performance.
Implementation Method 1
processed using the LFT-G method to enhance crystallinity
Implementation Method 2
a near-infrared laser beam passes through a laser-transmitting materials at an upper layer, and is absorbed by the laser-absorbing materials at a lower layer
Implementation Method 3
a near-infrared laser beam passes through a laser-transmitting materials at an upper layer, and is absorbed by the laser-absorbing materials at a lower layer to melt the plastic contact surface
Data Source
AI summary
A millimeter-wave radar housing material capable of being laser welded, and a preparation method therefor, which belong to the technical field of millimeter-wave radar housing manufacturing. The millimeter-wave radar housing material specifically comprises the following components in parts by weight: 50-90 parts of polypropylene, 10-50 parts of glass fiber, 0.2-0.8 part of a nucleating agent, 0.5-1 part of a compatibilizer, 0.1-0.5 part of a black colorant, 0.1-0.5 part of an antioxidant, and 0.1-0.8 part of a light stabilizer. The radar housing material disclosed by the present invention has the advantages of low dielectricity, being lightweight, high strength and high heat resistance, can transmit a near-infrared light beam, and has laser weldability.