CN107073774A - 雷达罩的制造方法以及雷达罩 - Google Patents

雷达罩的制造方法以及雷达罩 Download PDF

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Publication number
CN107073774A
CN107073774A CN201580050168.6A CN201580050168A CN107073774A CN 107073774 A CN107073774 A CN 107073774A CN 201580050168 A CN201580050168 A CN 201580050168A CN 107073774 A CN107073774 A CN 107073774A
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China
Prior art keywords
layer
gloss
recess
edge
radome
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Granted
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CN201580050168.6A
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CN107073774B (zh
Inventor
大竹信
大竹信一
远藤佳伸
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Faltec Co Ltd
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Faltec Co Ltd
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q1/00—Details of, or arrangements associated with, antennas
    • H01Q1/42—Housings not intimately mechanically associated with radiating elements, e.g. radome
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/7805—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features
    • B29C65/7814—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features in the form of inter-cooperating positioning features, e.g. tenons and mortises
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/545—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles one hollow-preform being placed inside the other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
    • B29C66/73365—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
    • G01S13/00—Systems using the reflection or reradiation of radio waves, e.g. radar systems; Analogous systems using reflection or reradiation of waves whose nature or wavelength is irrelevant or unspecified
    • G01S13/88—Radar or analogous systems specially adapted for specific applications
    • G01S13/93—Radar or analogous systems specially adapted for specific applications for anti-collision purposes
    • G01S13/931—Radar or analogous systems specially adapted for specific applications for anti-collision purposes of land vehicles
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
    • G01S7/00—Details of systems according to groups G01S13/00, G01S15/00, G01S17/00
    • G01S7/02—Details of systems according to groups G01S13/00, G01S15/00, G01S17/00 of systems according to group G01S13/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q1/00—Details of, or arrangements associated with, antennas
    • H01Q1/02—Arrangements for de-icing; Arrangements for drying-out ; Arrangements for cooling; Arrangements for preventing corrosion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q1/00—Details of, or arrangements associated with, antennas
    • H01Q1/27—Adaptation for use in or on movable bodies
    • H01Q1/32—Adaptation for use in or on road or rail vehicles
    • H01Q1/3208—Adaptation for use in or on road or rail vehicles characterised by the application wherein the antenna is used
    • H01Q1/3233—Adaptation for use in or on road or rail vehicles characterised by the application wherein the antenna is used particular used as part of a sensor or in a security system, e.g. for automotive radar, navigation systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7332—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured
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    • G01S2013/9327—Sensor installation details
    • G01S2013/93271—Sensor installation details in the front of the vehicles
    • G—PHYSICS
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    • G01S7/02—Details of systems according to groups G01S13/00, G01S15/00, G01S17/00 of systems according to group G01S13/00
    • G01S7/027—Constructional details of housings, e.g. form, type, material or ruggedness
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    • H01Q1/32—Adaptation for use in or on road or rail vehicles
    • H01Q1/325—Adaptation for use in or on road or rail vehicles characterised by the location of the antenna on the vehicle
    • H01Q1/3283—Adaptation for use in or on road or rail vehicles characterised by the location of the antenna on the vehicle side-mounted antennas, e.g. bumper-mounted, door-mounted

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Radar, Positioning & Navigation (AREA)
  • Remote Sensing (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Optics & Photonics (AREA)
  • Electromagnetism (AREA)
  • Computer Security & Cryptography (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Manufacturing & Machinery (AREA)
  • Radar Systems Or Details Thereof (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Vehicle Waterproofing, Decoration, And Sanitation Devices (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Details Of Aerials (AREA)

Abstract

一种雷达罩的制造方法，所述雷达罩覆盖检测车辆周围状况的雷达单元，包含以下工序，准备：基体部，具备由透明层形成的凹部并且在所述凹部以外的部分层叠配置有色层；光泽部件，具备在其表面具有光泽层的基部与缘部，配置所述基体部与所述光泽部件，使得所述光泽部件的所述缘部与所述基体部的所述有色层抵接，并且所述基部的所述光泽层与所述凹部对置，固定所述缘部与所述有色层。

Description

雷达罩的制造方法以及雷达罩
技术领域
本发明涉及雷达罩的制造方法以及雷达罩。
本申请基于2014年12月26日在日本申请的特愿2014－264081号主张优先权，在此引用其内容。
背景技术
近年在车辆上搭载有使用毫米波等的电波检测车辆周围的障碍物等的雷达单元。这样的雷达单元被配置在设置于车辆的前表面的散热器格栅或标志的内侧，进行穿透散热器格栅的电波的收发。因此，在具备上述那样的雷达单元的车辆中，散热器格栅或标志需要一边抑制电波的衰减，一边形成为能够使该电波穿透。
另一方面，因为散热器格栅或标志配置在车辆的前表面，所以是车辆的外观设计上极为重要的部分，为了提高高级感或质感而多赋予金属光泽性。以往，为了赋予这样的金属光泽性，一般施加镀敷处理，但是电波无法穿透镀敷层。因此，近年为了实现具有金属光泽性并且能够使电波穿透的构成，而使用形成电波能够穿透的金属制的蒸镀层或溅射层的技术。
例如，在专利文献1中，公开了具有金属光泽性并且电波能够穿透的天线罩(雷达罩)的制造方法。在这样的专利文献1中，利用嵌入成型将穿透雷达单元的光泽部件埋设在透明层与有色层之间，由此利用简易的工序制造雷达罩。
现有技术文献
专利文献
专利文献1：日本国特开2011-46183号公报
发明内容
发明要解决的技术问题
但是，在专利文献1中，因为利用嵌入成型埋设光泽部件，所以将光泽部件容纳在模具的内部。因此，光泽部件被暴露在嵌入成型时的高热中，形成于光泽部件的表面的光泽性层(蒸镀层或溅射层)存在受到嵌入成型时的热的影响而发生极小的变形或变色等的情况。在外观设计上特别重要的散热器格栅或标志，即便产生极小的变形或变色等的情况，也可能被判定为不良。因此，在专利文献1的方法中，可能会发生很多的不良品。
本发明鉴于上述的问题点而提出，目的在于抑制光泽部件因暴露在高温下而产生的外观不良，并实现雷达罩的成品率的提高。
用于解决上述技术问题的方案
本发明作为用于解决上述技术问题的手段，采用以下的构成。
本发明的第1方案的覆盖检测车辆周围状况的雷达单元的雷达罩的制造方法，包含以下工序，准备：基体部，具备由透明层形成的凹部并且在所述凹部以外的部分层叠配置有色层；光泽部件，具备在其表面具有光泽层的基部以及缘部，配置所述基体部与所述光泽部件，使得所述光泽部件的所述缘部与所述基体部的所述有色层抵接，并且所述基部的所述光泽层与所述凹部对置，固定所述缘部与所述有色层。
上述方案的雷达罩的制造方法，也可以还包括：利用双色成形而成型由树脂材料构成的所述透明层以及由与所述透明层不同的树脂材料构成的所述有色层，由此形成所述基体部。
也可以是，在所述缘部的与所述有色层抵接的抵接面和所述有色层的与所述缘部抵接的抵接面中的至少一方上，设置由树脂构成的突起部，在固定所述缘部与所述有色层时，通过使所述突起部熔融而使所述缘部焊接于所述有色层。
本发明的第2方案的覆盖检测车辆周围状况的雷达单元的雷达罩，具备：透明层，具备凹部；有色层，层叠配置于所述透明层的所述凹部以外的部分；光泽部件，具有在其表面具有光泽层的基部以及缘部，以所述光泽层与所述凹部对置的方式配置于所述凹部，所述缘部与所述有色层抵接并固定。
发明效果
根据本发明的上述方案，以避开透明层的凹部的方式层叠配置有有色层。因此，相对于透明层层叠配置了有色层之后，能够在凹部配置光泽部件。
因此，无需在透明层与有色层之间埋设光泽部件，就无需进行嵌入成型。此外，作为在有色层上固定光泽部件的方法，能够列举超声波或激光的焊接方法、使用热固化树脂等的粘结剂的固定方法等。根据这些方法，即便使用热进行固定，因为仅向固定部位处局部供热即可，所以与进行嵌入成型的情况相比较，能够大幅度地降低光泽部件的热负荷。因此，根据本发明的上述方案，大幅度地降低光泽部件的热负荷，抑制光泽部件因暴露于高温中而产生的外观不良，能够实现雷达罩的成品率的提高。
附图说明
图1是具备本发明的一实施方式的标志的散热器格栅的主视图。
图2是本发明的一实施方式的标志的放大主视图。
图3A是本发明的一实施方式的标志的剖视图。
图3B是本发明的一实施方式的光泽部件的剖视图。
图4A是示出本发明的一实施方式的标志的制造工序的概略图。
图4B是示出本发明的一实施方式的标志的制造工序的概略图。
图4C是示出本发明的一实施方式的标志的制造工序的概略图。
图4D是示出本发明的一实施方式的标志的制造工序的概略图。
图5A是图4B的局部放大图。
图5B是图4D的局部放大图。
图6A是示出本发明的一实施方式的标志的变形例的放大剖视图。
图6B是示出本发明的一实施方式的标志的变形例的放大剖视图。
图7A是示出本发明的一实施方式的标志具备的焊接肋的变形例的示意图。
图7B是示出本发明的一实施方式的标志具备的焊接肋的变形例的示意图。
图7C是示出本发明的一实施方式的标志具备的焊接肋的变形例的示意图。
图7D是示出本发明的一实施方式的标志具备的焊接肋的变形例的示意图。
具体实施方式
以下，参照附图对本发明的一实施方式的雷达罩的制造方法以及雷达罩进行说明。另外，在以下的附图中，为使各部件成为能够识别的大小，对各部件的比例尺进行了适当变更。
图1是具备由本实施方式的雷达罩构成的标志10的散热器格栅1的主视图。此外，图2是本实施方式的标志10的放大主视图。此外，图3A是本实施方式的标志10的剖视图。此外，图3B是本实施方式的光泽部件12的剖视图。
散热器格栅1以堵塞通向车辆发动机室的开口的方式设置在车辆的前表面，确保向发动机室的通风并且防止异物进入发动机室。在散热器格栅1的中央，以与配置在发动机室内的雷达单元R对置的方式设置有标志10。雷达单元R(参照图3A)，例如具有：发送毫米波的发送部、接收反射波的接收部以及进行运算处理的运算部等。雷达单元R进行穿透标志10的电波的收发，基于接收的电波检测车辆周围状况。例如，雷达单元R算出至障碍物的距离或障碍物的相对速度等并进行输出。
以从车辆的正面侧观察覆盖雷达单元R的方式配置标志10。如图2所示，从车辆的正面侧观察该标志10是具有以下区域的零件：光泽区域10A，展示示出车辆生产商的标志的图形或文字等；黑色区域10B，提高该光泽区域10A的视觉辨认性。如图3A所示，这样的标志10具备基体部11与光泽部件12。
基体部11具备：透明部11a(透明层)与黑色部11b(有色层)。透明部11a是由配置在车辆的最外侧的大致矩形状的透明材料形成的部位。为了提高从车辆的外部观察到的光泽部件12(光泽区域10A)的视觉辨认性，透明部11a正面侧的面形成为圆滑面。此外，在透明部11a的背面侧，形成有配置光泽部件12的凹部11a1。此外，在透明部11a的背面侧的面之中，没有设置凹部11a1的区域是与黑色部11b接触的接触面。
凹部11a1是容纳光泽部件12的部位，从车辆的前方侧能够立体地视觉辨认被容纳的光泽部件12。与车辆生产商的标志等的图形或文字等的形状对应地设置有凹部11a1。通过将光泽部件12容纳在凹部11a1中，形成光泽区域10A。
透明部11a由例如无色的PC(聚碳酸酯)或PNMA(聚甲基丙烯酸甲酯树脂)等的透明合成树脂形成即可。此外，透明部11a的厚度是1.5mm～10mm左右即可。此外，可以根据需要在透明部11a的正面侧的面上实施用于防止损伤的硬涂层处理、或者氨基甲酸乙酯类涂料的透明涂装处理。另外，只要是具备耐损伤性的透明合成树脂，就无需这些防止损伤处理。
黑色部11b是相对于透明部11a的背面侧的面层叠配置的层，是由黑色材料形成的部位。如图3A所示，黑色部11b避开凹部11a1地层叠配置于透明部11a(透明部11a的凹部11a1以外的部分)。即，黑色部11b以凹部11a1露出的方式具有开口11b1，以开口11b1与凹部11a1重叠的方式层叠配置在透明部11a的背面侧。此外，在黑色部11b中，在开口11b1上设置有台阶部11b3。台阶部11b3是沿着黑色部11b的开口11b1的区域，相对于其他的区域薄壁化地形成，是固定有光泽部件12的后述的凸缘12b的部位。此外，黑色部11b具有向发动机室侧突出的卡合部11b2。卡合部11b2的前端部成形为爪状，该前端部例如被卡止于散热器格栅主体。
像这样地相对于透明部11a的背面侧的面层叠配置的黑色部11b，能够从透明部11a的外侧视觉辨认，形成上述的黑色区域10B。即在视觉辨认时光泽区域10A以外的区域为黑色，黑色部11b相对地提高光泽区域10A的视觉辨认性。
黑色部11b只要是由ABS(丙烯腈-丁二烯-苯乙烯共聚合成树脂)、AES(丙烯腈-乙烯-苯乙烯共聚合成树脂)、ASA(丙烯腈-苯乙烯-丙烯酸酯)、PBT(聚对苯二甲酸丁二醇酯)、有色的PC、PET(聚对苯二甲酸乙二醇酯)等的合成树脂、或者是这些树脂的复合树脂构成即可。此外，黑色部11b的厚度是0.5mm～10mm左右即可。
具有透明部11a以及黑色部11b的基体部11是通过双色成形而形成的。例如先成形透明部11a，以避开凹部11a1的方式在先形成的透明部11a的背面侧的面上形成黑色部11b。通过这样的双色成形，能够容易地形成基体部11，所述基体部11由透明部11a与黑色部11b一体化地形成。但是，基体部11的形成方法不限定于双色成形，例如分别地对透明部11a与黑色部11b进行注射成型，通过粘结剂或焊接来将分体的透明部11a与黑色部11b固定，由此也能够形成基体部11。
如图3A以及3B所示，光泽部件12具备基部12a、凸缘12b、光泽层12c。通过注射成型等一体地形成基部12a与凸缘12b，例如通过ABS、PC或者PET等的合成树脂形成。基部12a是由于设置在凹部11a1内而埋设凹部11a1的部位。以形成于表面的光泽层12c与凹部11a1的内壁面接触的方式(以光泽层12c与凹部11a1对置的方式)形成基部12a。以包围基部12a的方式形成凸缘12b，从而形成光泽部件12的缘部。凸缘12b是抵接于设置在黑色部11b的台阶部11b3的部位。另外，如图3A以及3B所示，以比凸缘12b更向透明部11a侧突出的方式设置基部12a。
光泽层12c形成于基部12a的正面侧的面(透明部11a侧的面)，是具备金属光泽性的层。层叠使用金属蒸镀处理形成的金属层、用于保护该金属层的基础涂层以及表层涂层(均未图示)而形成光泽层12c。作为蒸镀处理能够使用真空蒸镀法或溅射法，作为蒸镀金属能够使用铟、铝或者锡等。基础涂层以及表层涂层通过蒸镀处理形成并保护薄的易碎的金属层。基础涂层以及表层涂层利用使用了透明(包含着色透明)的合成树脂的透明涂装形成。光泽层12c的金属层具有非常薄并且几乎难以目视的程度的多个间隙，具备充分的电波穿透性能。另外，光泽层12c并不限定于由上述的方法形成，也可以由具有充分的电波穿透性能并且能够具备金属光泽性的涂装以及其他的方法形成。
接着，对本实施方式的标志10的制造方法进行说明。图4A～4D是示出本实施方式的标志10的制造工序的概略图。
图4A是示出基体部形成工序的概略图。如图4A所示，在基体部形成工序中，进行基体部11的形成。例如，首先使用未图示的第1模具通过注射成型形成透明部11a，接着通过使用未图示的第2模具的注射成型将黑色部11b层叠配置于透明部11a。即，通过双色成形一体地形成由树脂材料构成的透明部11a以及由与该透明部11a颜色不同的树脂材料构成的黑色部11b。此时，在通过第1模具形成透明部11a时，相对于透明部11a形成有凹部11a1。此外，在通过第2模具形成黑色部11b时，避开凹部11a1形成黑色部11b。
图4B以及图4C是示出光泽部件形成工序的概略图。在光泽部件形成工序中，首先如图4B所示，通过注射成型一体地形成基部12a与凸缘12b。此时，如图4B的局部放大图即图5A所示，在凸缘12b与透明部11a的抵接面上，设置有焊接肋12d(树脂制的突起部)。焊接肋12d例如以包围基部12a的方式环状地设置，是在之后的工序中用于焊接透明部11a与凸缘12b而被熔融的部位。
接着，如图4C所示，在光泽部件形成工序中，相对于基部12a的正面侧的面形成光泽层12c。此处，例如从基部12a侧依次成膜基础涂层、金属层以及表层涂层，由此形成光泽层12c。例如通过使用了透明合成树脂的透明涂装来形成基础涂层以及表层涂层，通过金属蒸镀处理形成金属层。
另外，因为凸缘12b的正面侧的面(车辆的前方侧的面)与黑色部11b抵接，所以无法从外部通过透明部11a视觉辨认到。因此，无需相对于凸缘12b的正面侧的面而形成光泽层12c。因此，在形成光泽层12c时，也可以对凸缘12b的表面进行掩模。但是，光泽层12c较薄，在之后进行的焊接透明部11a与凸缘12b的工序中，因热被剥离。因此，即便不进行掩模，也可以在凸缘12b的正面侧的面形成光泽层12c，较为简便。
此外，图4A所示的基体部形成工序与图4B以及图4C所示的光泽部件形成工序是能够独立地进行的作业工序。因此，为了缩短制造时间，优选是并行地进行基体部形成工序与光泽部件形成工序。
图4D是示出光泽部件配置工序的概略图。如图4D所示，在光泽部件配置工序中，首先将在上述光泽部件形成工序中形成的光泽部件12配置成容纳于在上述的基体部形成工序中形成的基体部11的凹部11a1。此时，如图5B所示，以光泽部件12的焊接肋12d抵接于基体部11的黑色部11b具有的台阶部11b3的方式，相对于凹部11a1配置光泽部件12(配置工序)。
其次，使焊接肋12d熔融而相对于黑色部11b焊接光泽部件12(固定工序)。若使焊接肋12d熔融，则焊接肋12d因熔融而扩散，由此光泽部件12接近透明部11a侧，使得光泽层12c抵接于凹部11a1的内壁面。
此处，例如通过超声波焊接法或激光穿透焊接法等相对于黑色部11b焊接光泽部件12。在使用超声波焊接法的情况下，例如相对于光泽部件12赋予超声波振动，通过该振动在焊接肋12d与黑色部11b的界面产生摩擦热。进而，通过该摩擦热使焊接肋12d熔融，之后通过冷却使光泽部件12相对于黑色部11b焊接。此外，在激光穿透焊接法中，例如通过激光能够穿透的材料形成光泽部件12。进而，从光泽部件12的背面侧将激光照射在焊接肋12d上，由此使焊接肋12d熔融，之后通过冷却使光泽部件12相对于黑色部11b焊接。
通过以上那样的工序制造本实施方式的标志10。根据本实施方式的标志10以及该标志10的制造方法，以避开透明部11a的凹部11a1的方式层叠配置黑色部11b。因此，相对于透明部11a层叠配置了黑色部11b后，能够在凹部11a1配置光泽部件12。因此，无需以在透明部11a与黑色部11b之间夹着光泽部件12的方式埋设光泽部件12，从而无需进行嵌入成型。此外，光泽部件12向黑色部11b的固定能够通过超声波或激光的焊接方法进行。
根据这些方法，因为仅向固定部位处局部供热即可，与进行嵌入成型的情况相比，能够大幅度地降低对光泽部件12(即光泽层12c)的热负荷。因此，根据本实施方式的标志10以及该标志10的制造方法，大幅度地降低对光泽部件12的热负荷，抑制光泽部件12因暴露于高温而产生的外观不良，能够实现提高标志10的成品率。
此外，在本实施方式的标志10的制造方法中，在基体部形成工序中，通过双色成形成型由树脂材料构成的透明部11a以及由与透明部11a颜色不同的树脂材料构成的黑色部11b，由此形成基体部11。因此，能够容易地使透明部11a与黑色部11b一体化，能够在短时间内形成基体部11。
此外，在本实施方式的标志10的制造方法中，在使光泽部件12的凸缘12b从与透明部11a相反的一侧抵接于黑色部11b的状态下，将光泽部件12配置于凹部11a1，使光泽部件12的凸缘12b与黑色部11b固定。因此，仅将光泽部件12的一部分(即凸缘12b)固定于黑色部11b即可，能够进一步抑制在固定时对光泽部件12的影响。
此外，在本实施方式的标志10的制造方法中，在光泽部件12的凸缘12b与黑色部11b的抵接面上设置有焊接肋12d。进而，通过使焊接肋12d熔融，使光泽部件12焊接在黑色部11b上。因此，无需直接地加热凸缘12b本身，能够防止在凸缘12b等上产生缩痕。
以上虽然参照附图对本发明的优选的实施方式进行了说明，但本发明不限定于上述实施方式。在上述实施方式中示出的各构成部件的各形状或组合等是一例，在不脱离本发明的主旨的范围内基于设计要求等可能会存在各种变更。
例如，在上述实施方式中，对抵接有凸缘12b的黑色部11b的抵接面为平面的构成进行了说明。但是，本发明并不限定于此，例如如图6A所示，也可以设置与焊接肋12d嵌合的槽部11c。通过设置这样的槽部11c，能够容易地进行焊接前的光泽部件12的定位。另外，也可以在黑色部11b侧设置焊接肋。
此外，如图6B所示，也可以设置多个焊接肋12d以及槽部11c。此时，槽部11c不是必须的，也可以与上述实施方式同样地使黑色部11b的抵接面为平面。像这样地通过设置多个焊接肋12d，能够相对于黑色部11b进一步牢固地固定光泽部件12。在上述实施方式的标志10中，因为不存在压制光泽部件12的背面侧的面的部件，所以通过像这样地相对于黑色部11b进一步牢固地固定光泽部件12，能够可靠地防止光泽部件12的剥离等。此外，为了像这样地相对于黑色部11b进一步牢固地固定光泽部件12，无论在使用何种焊接方法的情况下，都优选一边将光泽部件12向黑色部11b侧按压，一边进行焊接。
此外，在上述实施方式中，采用了具有呈环状地包围光泽部件12的基部12a的焊接肋12d的构成。但是，本发明并不限定于此。例如如图7A所示，也能够采用一边使切口方向变化、一边沿着凸缘12b排列多个C形的焊接肋12d1的构成。此外，如图7B所示，也能够采用使姿势变化并沿着凸缘12b排列多个大致S型的焊接肋12d2的构成。此外，如图7C所示，也能够采用使姿势变化并沿着凸缘12b排列多个半圆弧状的的焊接肋12d3的构成。此外，如图7D所示，也能够采用使姿势变化并沿着凸缘12b排列多个焊接肋12d4的构成，所述焊接肋12d4由并行地排列的3个棒状部构成。根据这样的焊接肋12d1～12d4，因为呈各种各样的姿势，所以能够使熔融时的软化扩展均匀化，能够抑制在凸缘12b等中产生缩痕。
此外，在上述实施方式中，对使黑色部11b与光泽部件12焊接的构成进行了说明。但是，本发明并不限定于此，也能够采用使用粘结剂固定黑色部11b与光泽部件12的构成。
此外，在上述实施方式中，采用了通过双色成形一体地形成透明部11a与黑色部11b的构成。但是，本发明并不限定于此，也可以通过粘结剂等固定透明部11a与黑色部11b。
此外，也能够采用使用其他颜色的有色部(有色层)的构成，而非黑色部11b。
此外，在上述实施方式中，对本发明的雷达罩为标志10的构成进行了说明。但是，本发明并不限定于此。例如，也能够采用如下的构成：将散热器格栅的其他的一部分或者全部作为本发明的雷达罩。
附图标记说明
1 散热器格栅
10 标志(雷达罩)
11 基体部
11a 透明部(透明层)
11a1 凹部
11b 黑色部(有色层)
12 光泽部件
12a 基部
12b 凸缘(缘部)
12c 光泽层
12d 焊接肋
12d1～12d4 焊接肋

Claims (4)

1.一种雷达罩的制造方法，所述雷达罩覆盖检测车辆周围状况的雷达单元，
准备基体部与光泽部件，所述基体部具备由透明层形成的凹部并且在所述凹部以外的部分层叠配置有色层，所述光泽部件具备在表面具有光泽层的基部以及缘部，
配置所述基体部与所述光泽部件，使得所述光泽部件的所述缘部与所述基体部的所述有色层抵接，并且所述基部的所述光泽层与所述凹部对置，
固定所述缘部与所述有色层。
2.如权利要求1所述的雷达罩的制造方法，其特征在于，还包括：利用双色成形而成型由树脂材料构成的所述透明层以及由与所述透明层不同的树脂材料构成的所述有色层，由此形成所述基体部。
3.如权利要求1或2所述的雷达罩的制造方法，其特征在于，在所述缘部的与所述有色层抵接的抵接面和所述有色层的与所述缘部抵接的抵接面中的至少一方上，设置由树脂构成的突起部，
在固定所述缘部与所述有色层时，通过使所述突起部熔融而使所述缘部焊接于所述有色层。
4.一种雷达罩，覆盖检测车辆周围状况的雷达单元，其特征在于，具备：
透明层，具备凹部；
有色层，层叠配置于所述透明层的所述凹部以外的部分；
光泽部件，具有在其表面具有光泽层的基部以及缘部，以所述光泽层与所述凹部对置的方式配置于所述凹部，所述缘部与所述有色层抵接并固定。
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