Radio Wave Transmitting Decorative Member with Aluminum Alloy
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Solution Overview
Problem
Existing decorative members with metallic luster that transmit radio waves face issues such as high production costs, loss of luster due to oxidation, and limited frequency compatibility, while current solutions either reflect or absorb radio waves depending on film thickness and material properties.
Innovation Solution
A radio wave transmitting decorative member is created using a substrate with a transparent organic material layer and a light reflecting layer formed from an alloy of silicon or germanium and a metal, which is deposited using DC magnetron sputtering, ensuring efficient transmission and maintaining metallic luster without oxidation, and includes optional low refractive index and adhesion promoting layers for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the thickness of the metal deposited film is increased to attain satisfactory metallic luster, then the metallic luster is improved, but the islands become partially connected forming a conductive network that reflects or absorbs radio waves
Solution Approach 1:
The patent changes the material composition parameter from conventional metals (indium, tin) to aluminum, and controls the film thickness parameter within a specific range (5-100 nm) to achieve both metallic luster and radio wave transmission without forming conductive networks
Solution Approach 2:
The patent uses a composite structure consisting of an aluminum-based metal deposited film combined with an organic compound layer, where the organic compound prevents oxidation and maintains the metal's reflective properties while allowing radio wave transmission
2Illumination intensity
If tin is used for metallic luster, then the luster is achieved, but tin is prone to oxidation and chlorination causing loss of luster over time
Solution Approach 1:
The patent uses aluminum, which is cheaper than indium and more stable than tin against oxidation, providing a cost-effective and durable solution for maintaining metallic luster
Solution Approach 2:
The patent creates a composite structure with aluminum metal and organic compound layer, where the organic compound acts as a protective barrier preventing oxidation and chlorination, thereby maintaining metallic luster over time
3Reliability
If indium is used for metallic luster and radio wave transmission, then both properties are achieved, but indium is highly expensive
Solution Approach 1:
The patent replaces expensive indium with aluminum, which is abundant and cost-effective, while maintaining both metallic luster and radio wave transmission properties through optimized film thickness and composite structure
Solution Approach 2:
The patent changes the material from indium to aluminum and optimizes the film thickness parameter to achieve the desired balance between metallic luster, radio wave transmission, and cost-effectiveness
4Reliability
If a reflective film with openings is used for radio wave transmission, then radio waves can pass through, but only specific frequencies conforming to the opening size can pass
Solution Approach 1:
The patent changes the approach from using openings in reflective film to using a continuous thin metal film with controlled thickness (5-100 nm) combined with organic compound layer, which allows broad frequency range radio wave transmission without limiting to specific frequencies
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 provides stable, cost-effective production of decorative members with both radio wave transmission and mirror-surface metallic luster, maintaining luster over time and ensuring minimal interference across various frequencies.
Implementation Method 1
a light reflecting layer formed of an alloy composed of either silicon or germanium and a metal... providing both radio wave transmitting properties and metallic luster
Implementation Method 2
The light reflecting layer is formed from a target having an alloy composed of either silicon or germanium, and of a metal by using DC magnetrons spattering
Implementation Method 3
maintaining luster over time... hardly loses its metallic luster
Implementation Method 4
a low refractive index layer having a lower refractive index than that of the transparent organic material later, provided between the transparent organic material layer and the light reflecting layer
Data Source
AI summary
The radio wave transmitting decorative member and the method of producing thereof efficiently and stably of the present invention is provided with radio wave transmitting properties as well as mirror-surface like metallic luster, hardly loses its metallic luster, and can be produced at a low cost. The method of producing a radio wave transmitting decorative member, having a substrate, a transparent organic material layer, and a light reflecting layer formed of an alloy composed of either silicon or germanium and a metal provided between the substrate and the transparent organic material layer; wherein the light reflecting layer is formed from a target having an alloy composed of either silicon or germanium, and of a metal with the use of a DC magnetrons sputtering.