Resin Composition with Uneven Filler Distribution for Millimeter Wave Transparency

Solution Overview

Problem

In resin compositions and sparkle coating films, increasing the content rate of sparkle materials or fillers with higher relative permittivity or conductivity reduces electromagnetic wave transparency, compromising both aesthetic and functional properties.

Innovation Solution

A resin composition with unevenly distributed filler particles, such as aluminum flakes, is used to maintain electromagnetic wave transparency while enhancing aesthetic properties. The filler particles have a higher relative permittivity or conductivity than the base resin and are distributed to maximize inter-particle distances, allowing for effective millimeter wave transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the content rate of sparkle material is increased to enhance aesthetic properties, then the sparkling effect is improved, but electromagnetic wave transparency is reduced

Engineering Contradiction:

Improvesparkling effectVSAvoidelectromagnetic wave transparency

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The patent applies local quality by creating regions with different filler particle concentrations. Specifically, it defines a first region with a first filler particle content rate and a second region with a second filler particle content rate that is lower than the first. This non-uniform distribution allows the coating to maintain high sparkle effect in certain areas while preserving electromagnetic wave transparency in others, thereby resolving the contradiction between aesthetic properties and functional performance.

Inventive Principle:

Principle #3Local quality

2Illumination intensity

If filler particles with higher relative permittivity or conductivity are added to enhance aesthetic properties, then the sparkling effect is improved, but electromagnetic wave transparency is reduced

Engineering Contradiction:

Improvesparkling effectVSAvoidelectromagnetic wave transparency

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The patent applies local quality by creating regions with different filler particle concentrations. Specifically, it defines a first region with a first filler particle content rate and a second region with a second filler particle content rate that is lower than the first. This non-uniform distribution allows the coating to maintain high sparkle effect in certain areas while preserving electromagnetic wave transparency in others, thereby resolving the contradiction between aesthetic properties and functional performance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies parameter changes by varying the filler particle content rate across different regions of the coating. It specifies that the second filler particle content rate is lower than the first, and further refines this by setting specific ranges (e.g., the second content rate may be 0.5 to 2.0 times the first content rate). This parameter variation optimizes the balance between sparkle effect and electromagnetic wave transparency.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If uniform distribution of filler particles is used, then manufacturing simplicity is maintained, but electromagnetic wave transparency is reduced due to higher overall filler content required for aesthetic effect

Engineering Contradiction:

Improvedistribution uniformityVSAvoidelectromagnetic wave transparency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by creating regions with different filler particle concentrations. Specifically, it defines a first region with a first filler particle content rate and a second region with a second filler particle content rate that is lower than the first. This non-uniform distribution allows the coating to maintain high sparkle effect in certain areas while preserving electromagnetic wave transparency in others, thereby resolving the contradiction between aesthetic properties and functional performance.

Inventive Principle:

Principle #3Local quality

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 resin composition achieves sufficient millimeter wave transparency with two-way transmission attenuation of 5.0 dB or less, while maintaining a high sparkling effect and aesthetic properties, by optimizing the distribution and content rate of filler particles.

Implementation Method 1

The filler particles have a higher relative permittivity than the base resin or have conductivity

Methodology Applied

Scientific EffectRelative permittivity: Dielectric Permittivity

Implementation Method 2

The filler particles have a higher relative permittivity than the base resin or have conductivity

Methodology Applied

Scientific EffectConductivity: Conduction (electrical)

Implementation Method 3

achieves sufficient millimeter wave transparency with two-way transmission attenuation of 5.0 dB or less

Methodology Applied

Scientific EffectElectromagnetic wave transmission: Electromagnetic Induction

Data Source

PatentUS20250154369A1Resin composition

Publication Date: 2025.05.15 TOYODA GOSEI CO LTD

AI summary

A resin composition having electromagnetic wave transparency includes a base resin and filler particles added to the base resin. The filler particles have a higher relative permittivity than the base resin or have conductivity. The filler particles are unevenly distributed in the resin composition.