Vehicle Radio Wave Cover Coating for 3D Design Clarity
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Solution Overview
Problem
Existing methods for forming a metal layer on the uneven surface of a transparent resin layer in radio wave transmission covers for vehicles result in reduced radio wave transmission performance due to uneven attenuation and phase differences, and suffer from inaccuracies in positioning the metal layer, leading to poor appearance and design clarity.
Innovation Solution
A manufacturing method involving the use of a first layer on the stepped and inclined portions of the transparent resin layer, followed by laser irradiation to separate excess parts, and a second layer to cover the remaining areas, ensuring accurate placement and alignment of the metal layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the entire surface of the transparent resin layer is covered with the indium layer, then the three-dimensional characters or figures can be expressed, but the radio wave transmission performance is reduced due to large attenuation and phase difference
Solution Approach 1:
The patent applies local quality by making the indium layer thickness non-uniform: thicker in concave parts (for 3D character expression) and thinner or absent in convex parts (for radio wave transmission). This spatial variation in layer properties resolves the contradiction between achieving three-dimensional appearance and maintaining radio wave transmission performance.
2Ease of manufacture
If the screen printing method is used to print the indium layer, then the indium can be partially printed in the concave part, but the boundary of the print part shifts when the screen mesh position is slightly shifted, resulting in poor appearance
Solution Approach 1:
The patent uses preliminary action by first forming an uneven surface structure with defined concave and convex parts through molding. This pre-established geometric framework guides subsequent indium layer deposition, ensuring that even if printing positioning has slight variations, the indium will be deposited in the correct concave regions due to the physical structure guidance, thereby maintaining boundary accuracy.
3Ease of manufacture
If the hot stamping method is used to transfer the indium layer, then the indium can be transferred to the uneven surface, but transfer errors such as non-attachment occur
Solution Approach 1:
The patent replaces the mechanical hot stamping transfer process with a direct deposition method where indium is deposited onto the uneven surface through vacuum deposition or similar techniques. This substitution eliminates the intermediate transfer step that causes positioning errors and non-attachment issues, achieving more accurate and reliable indium layer formation directly on the target surface.
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
This method allows for precise formation of designs on uneven surfaces with minimal interference to radio wave transmission, maintaining good appearance and clarity, while overcoming inaccuracies associated with traditional printing methods.
Implementation Method 1
separating an excess part, other than the covering the stepped portion, in the first layer by laser irradiation
Data Source
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AI summary
A decorative member includes: a transparent resin layer provided on a rear surface thereof with a general portion, a stepped portion recessed or protrudingly provided with respect to the general portion, and an inclination portion provided between the stepped portion and the general portion; and a decorative layer provided on the rear surface, wherein: an inclination angle of the inclination portion with respect to a normal line of the general portion is equal to or more than 25° and is equal to or less than 40°; a width of the inclination portion is large beyond 0.38 mm and is equal to or less than 1 mm; and the decorative layer includes: a first layer that covers the stepped portion of the rear surface; and a second layer that covers a part of the rear surface, which is not covered by at least the first layer.