Vehicle Radome Defrosting System with Folded Support Sheet
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Solution Overview
Problem
Existing defrosting systems for vehicle radomes, which use heating tracks to prevent frost interference with sensors, are aesthetically unpleasing and inefficient due to the visible connecting devices and extended heating tracks required for peripheral placement.
Innovation Solution
A method involving a support sheet with a connecting organ and heating track forming an angle between 65° and 115°, overmolded with thermoplastic materials to position the connecting device out of sight, allowing for a more flexible and efficient defrosting system placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connecting device is arranged at the periphery of the radome to supply the heating track, then the heating track can be positioned near the outer surface for efficient defrosting, but the connecting device becomes visible from outside and requires an additional crown part to hide it, increasing device complexity and manufacturing cost
Solution Approach 1:
The support sheet is folded to form a dihedral angle between 65° and 115°, creating a three-dimensional configuration where the connecting device is positioned on a different plane than the heating track. This spatial separation allows the connecting device to be hidden on the inner surface while the heating track remains visible on the outer surface, eliminating the need for additional hiding structures.
2Ease of operation
If the connecting device is arranged at the periphery of the radome, then it can be connected to power sources, but the heating track must be extended to reach it, causing loss of heating efficiency
Solution Approach 1:
By folding the support sheet to create a dihedral angle, the connecting device and heating track are positioned in different spatial zones. This allows the heating track to be placed optimally near the outer surface for maximum defrosting efficiency while the connecting device is positioned on the inner surface where it can be accessed for power connection, eliminating the need for extended heating tracks.
3Ease of manufacture
If the connecting device is placed on the same side as the heating track for easier assembly, then assembly is simplified, but the connecting device becomes visible from outside creating aesthetic issues
Solution Approach 1:
The support sheet is folded along a fold line to form a dihedral angle, creating two distinct surfaces: an outer surface where the heating track is positioned for aesthetic visibility, and an inner surface where the connecting device is positioned for aesthetic concealment. This maintains assembly simplicity while resolving the aesthetic conflict through spatial separation.
4Adaptability or versatility
If the heating track is extended to reach the peripherally positioned connecting device, then connection is possible, but the heating track length increases causing greater energy loss
Solution Approach 1:
The folded support sheet creates a three-dimensional configuration where the heating track and connecting device are positioned on different planes. This allows the heating track to maintain an optimal, minimal length for efficient heat transfer while the connecting device is positioned for flexible placement on the inner surface, eliminating energy losses from extended tracks.
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 an aesthetically pleasing and efficient defrosting system by hiding the connecting device and maintaining heating track proximity to the surface, enhancing defrosting effectiveness and simplifying assembly.
Implementation Method 1
a heating track, consisting of conductive wires capable of transforming electrical energy into thermal energy
Implementation Method 2
a first thermoplastic material is injected into the first molding chamber to obtain a first layer
Data Source
Figure 1~4
AI summary
The invention relates to a method for manufacturing a component (1) for a bodywork part comprising successively the following steps: - step A: a support sheet (10) is produced comprising a first zone (11) in which a connecting member (12) is arranged and a second zone (13) in which a heating track (14) is arranged which is connected to the connecting member (12); - step B: the shape of the support sheet (10) is modified so that the first zone (11) and the second zone (13) form an angle (a) which is between 65° and 115°; - step C: the support sheet (10) is placed in a first molding chamber and a first thermoplastic material is injected into the first molding chamber to obtain a first layer (20) overmolded onto the support sheet (20), the first layer (20) covering the entire second zone (13);- step D: the support sheet (10) is placed in a second molding chamber and a second thermoplastic material is injected into the second molding chamber to obtain a second layer (30) overmolded on the first layer (20).