Radar-Transparent Vehicle Exterior With Heater Sheet Layout

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Solution Overview

Problem

The challenge is to accurately form a heater sheet with a body corresponding to the bend surface of a vehicle exterior part, which is difficult due to the extensive curvature or angles of the bend surface, and to integrate this sheet into a mold for molding the transparent resin layer while maintaining the desired shape.

Innovation Solution

The vehicle exterior part incorporates a heater sheet with a transparent sheet base and heater wires arranged on it, where the heater wires generate heat when energized. The sheet base includes a body in front of the transparent resin layer and an extension, with the heater wires supplied at the extension. The body and heater wire portions are located in front of only the general surface, simplifying the shape correspondence and mold integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the heater sheet body is formed to correspond to the bend surface shape, then the snow-melting function is improved, but the manufacturing precision deteriorates due to difficulty in accurately forming the curved/angular shape

Engineering Contradiction:
Improvesnow-melting functionVSAvoidshape correspondence accuracy
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent extracts the heater sheet body from the transparent resin layer, allowing them to be manufactured and positioned independently. The heater sheet body is formed separately with extended portions that protrude toward the front surface, then integrated into the transparent resin layer. This separation enables the heater sheet to achieve the necessary shape correspondence with the bend surface without compromising manufacturing precision, as the extended portions can be designed with sufficient protrusion distance to ensure contact with the bend surface while being manufactured as a distinct component.

Inventive Principle:
Principle #2Taking out (Extraction)

2Reliability

If the heater sheet body is formed to correspond to the bend surface shape, then the snow-melting function is improved, but the device complexity increases due to difficulty in arranging and integrating the sheet into the mold

Engineering Contradiction:
Improvesnow-melting functionVSAvoidmold integration complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The heater sheet is segmented into a base portion and extended portions that protrude toward the front surface. This segmentation allows the extended portions to be designed independently to achieve the necessary shape correspondence with the bend surface. The segmented structure simplifies mold integration, as the extended portions can be positioned and fixed within the mold cavity before the transparent resin layer is formed, reducing the overall device complexity while maintaining effective snow-melting function.

Inventive Principle:
Principle #1Segmentation

3Use of energy by moving object

If the heater sheet is arranged in close contact with the transparent resin layer, then the heat transfer efficiency is improved, but the ease of manufacture deteriorates due to difficulty in forming the body shape

Engineering Contradiction:
Improveheat transfer efficiencyVSAvoidbody formation ease
Core Design Contradiction:
Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The heater sheet body is preliminarily formed with extended portions that protrude toward the front surface before integration into the transparent resin layer. This preliminary action ensures that the extended portions are already positioned to achieve close contact with the bend surface, maximizing heat transfer efficiency. The pre-formed extended portions simplify the subsequent manufacturing process, as they can be directly integrated into the mold without requiring complex shaping operations, thereby improving ease of manufacture while maintaining effective heat transfer to the bend surface for snow-melting function.

Inventive Principle:
Principle #10Preliminary action

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 efficient melting of ice and snow, maintaining the detection performance of millimeter wave radar devices by preventing wave attenuation, while also simplifying the formation and integration of the heater sheet into the vehicle exterior part.

Implementation Method 1

The heater wire generates heat when energized

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The decoration body permits the passage of millimeter waves

Methodology Applied
Scientific EffectElectromagnetic wave transmission: Electromagnetic Induction

Data Source

PatentUS12311850B2Vehicle exterior part
Publication Date: 2025.05.27 TOYODA GOSEI CO LTD
  • US12311850B2 patent drawing
  • US12311850B2 patent drawing
  • US12311850B2 patent drawing

AI summary

A vehicle exterior part includes a decoration body including a layer structure formed by laminating layers in a front-rear direction, and includes a heater sheet including a transparent sheet base and a heater wire. The decoration body includes a transparent resin layer at a frontmost part of the decoration body and a decorative layer located rearward from the transparent resin layer. The transparent resin layer includes a general portion and an outer edge. A front surface of the general portion includes a general surface. The outer edge includes a bend surface that is curved or angular to a larger extent than the general surface. The sheet base includes a body located in front of the transparent resin layer and an extension extending from a periphery of the body. The body and a portion of the heater wire arranged on the body are located in front of only the general surface.