Radio Wave Transmittable Sensor Cover with Micro Cracks and Laser Holes
Solution Overview
Problem
Conventional sensor covers made of metals like indium, tin, or gallium face challenges with high cost, limited reserves, and poor reliability in terms of oxidation resistance, water resistance, and radio wave transmissivity, while also being difficult to integrate with surrounding components due to their continuous structure.
Innovation Solution
A manufacturing method for a radio wave transmittable sensor cover that incorporates micro cracks and a laser hole pattern in a metal layer, allowing for the use of any metal material, including those with high conductivity, by forming an island structure through thermal stress and laser punching, which enhances radio wave transmissivity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous metal layer is used for the sensor cover, then strength and weather resistance are improved, but radio wave transmissivity deteriorates
Solution Approach 1:
The metal layer is segmented into an island structure with micro-cracks and laser holes, dividing the continuous metal into isolated regions. This segmentation allows the metal layer to maintain structural strength while creating pathways for radio wave transmission through the gaps between islands, micro-cracks, and laser holes.
Solution Approach 2:
The metal layer is designed with a porous structure containing micro-cracks and laser holes distributed throughout. This porous configuration enables radio waves to pass through the material while the remaining metal framework maintains mechanical strength and protective functions.
2Reliability
If conventional metals like indium, tin, or gallium are used, then radio wave transmissivity is improved, but cost and reliability deteriorate
Solution Approach 1:
The invention changes the structural parameters of the metal layer rather than relying on specific material properties. By controlling the morphology (island structure), dimensions (micro-crack patterns, laser hole sizes and distributions), and configuration of the metal layer, radio wave transmissivity is achieved without being constrained by material selection, enabling use of cost-effective metals.
Solution Approach 2:
The sensor cover employs a composite structure combining metal layer with polymer resin or glass fiber reinforcement. This composite approach allows the use of inexpensive metals while achieving both mechanical strength and radio wave transmissivity through the synergistic combination of materials and structural design.
3Reliability
If a metal layer with island structure is formed, then radio wave transmissivity is improved, but manufacturing complexity increases
Solution Approach 1:
The island structure is formed as a preliminary step during the metal layer deposition process itself, rather than requiring subsequent complex machining or drilling operations. The micro-cracks and laser holes are integrated into the manufacturing workflow, simplifying the overall process despite the complex final structure.
Solution Approach 2:
Traditional mechanical methods for creating holes or patterns in metal layers are replaced with laser technology. Laser holes can be precisely formed directly during or after deposition without mechanical drilling, reducing manufacturing complexity and enabling the intricate island structure to be produced efficiently.
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 method enables the use of cost-effective, reliable metals with high conductivity for the sensor cover, ensuring radio wave transmissivity and continuity with surrounding components while maintaining strength and durability.
Implementation Method 1
the substrate with the metal layer and the primer coating layer is heat-treated at a second temperature relatively lower than the first temperature after deposition of the metal layer, and as a result, micro cracks are formed on the metal layer by a difference in thermal stress between the substrate and the metal layer
Implementation Method 2
a hole pattern including a plurality of holes which are vertically penetrated by laser punching is formed to correspond to a thickness of the metal layer with the micro cracks to remove bindings between the columnar crystals of the metal layer
Implementation Method 3
forming a metal layer having an island structure to be located on the upper surface of the primer coating layer by a physical vapor deposition or chemical vapor deposition method
Implementation Method 4
forming a metal layer having an island structure to be located on the upper surface of the primer coating layer by a physical vapor deposition or chemical vapor deposition method
Data Source
AI summary
Provided is a radio wave transmittable laminate, which includes a substrate; a primer coating layer located on an upper surface of the substrate and including a polymer resin; a metal layer located on an upper surface of the primer coating layer and made of a metal; a plurality of micro cracks formed in the metal layer so as to transmit radio waves; and a hole pattern constituted by a plurality of holes which vertically penetrate the metal layer so as to transmit the radio waves.