Vehicle Radome with Embedded Logo and Thin Metallic Layer
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Solution Overview
Problem
Existing methods for manufacturing radomes for motor vehicle distance warning radars with integrated design elements are complex and costly, often resulting in air inclusions that can cause interference and require expensive scratch and UV-resistant coatings.
Innovation Solution
A method involving a thermoplastic or duroplastic carrier with a three-dimensional design element and a visually transparent coating, where the design element is embedded within the radome using a simple process involving spraying or dipping, ensuring radar transparency and exclusion of air inclusions, with a metallic layer for visibility and radar wave reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If joining technology is used to create radome covers, then the radome can be manufactured with separate components, but air inclusions occur that cause interference and require expensive corrections
Solution Approach 1:
The patent merges the carrier and design element into a single integrated component produced by injection molding. The design element is formed directly within the carrier material during the molding process, eliminating the need for separate joining operations and preventing air inclusions that would interfere with radar passage.
Solution Approach 2:
The patent segments the radome into a carrier portion and a design element portion that are formed in one piece. The design element is created as a distinct feature within the carrier material, allowing functional separation while maintaining structural integration to avoid air inclusions.
2Reliability
If a visually transparent coating is applied to protect the radome surface, then scratch and UV resistance is improved, but the cost and manufacturing complexity increase significantly
Solution Approach 1:
The patent applies the visually transparent coating during the injection molding process itself, before the radome is completed. The coating is introduced into the mold cavity along with the plastic material, allowing the coating to be applied preliminarily as the radome takes shape, eliminating subsequent coating operations.
Solution Approach 2:
The patent combines the coating application step with the injection molding process. The coating material is mixed with or applied to the plastic material during molding, merging two manufacturing operations into one to reduce complexity and cost while maintaining surface protection.
3Illumination intensity
If a thick metallic layer is applied to create a shiny design element, then visibility and aesthetic appearance are improved, but radar wave transmission is blocked
Solution Approach 1:
The patent changes the thickness parameter of the metallic layer to a specific range (5-50 nanometers) that allows visual reflection while maintaining radar wave transmission. This precise parameter control enables the metallic layer to serve both aesthetic and functional purposes simultaneously.
Solution Approach 2:
The patent applies the metallic layer only to specific areas of the design element where visual appearance is desired, while maintaining radar transparency in those same areas through controlled thickness. The metallic coating is localized to the design element surface rather than the entire radome.
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 a resource-saving, interference-free radome with retained imaging properties and radar transparency, eliminating the need for complex joining technologies and expensive coatings, while maintaining the vehicle's appearance and radar functionality.
Implementation Method 1
the thickness of the metallic or metallically shiny layer being such that the electromagnetic radiation is completely absorbed in the visible wavelength range is reflected
Implementation Method 2
the electromagnetic radiation is completely absorbed in the visible wavelength range
Implementation Method 3
an extremely thin layer vapor-deposited on one of the layers that acts as a carrier
Data Source
Figure 1
AI summary
The invention relates to a radome for a distance warning radar on a motor vehicle, comprising a design element, e.g. a logo, which is visible from the outside and is integrated into the radome, as well as to a method for manufacturing said radome.