Classifications

• • 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
  • B29C45/1671—Making multilayered or multicoloured articles with an insert
• • 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
  • B29C45/1675—Making multilayered or multicoloured articles using exchangeable mould halves
• • 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
  • G01S7/027—Constructional details of housings, e.g. form, type, material or ruggedness
• • 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
  • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
  • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection 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
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
  • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
• • 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
  • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
  • B29C45/14819—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being completely encapsulated
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2009/00—Layered products
  • B29L2009/003—Layered products comprising a metal layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
  • B29L2031/3456—Antennas, e.g. radomes
• • 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
  • G01S2013/9327—Sensor installation details
  • G01S2013/93271—Sensor installation details in the front of the vehicles

Definitions

• the invention relates to a method of manufacturing a plastic part.
• the invention relates more particularly to a method of manufacturing a part for a vehicle whether it is a motor vehicle or human powered.
• the invention also relates to a part obtained by the manufacturing method.
• the invention also relates to an assembly of a vehicle radar equipped with a part obtained by the manufacturing method and a vehicle equipped with such an assembly.
• a decorative radome which may be the emblem or the logo of the front grille, for a motor vehicle by independent molding of two parts and assembly of these two pieces by gluing.
• a decorative film is placed on one of the two pieces before gluing so that the film is caught between the two pieces after gluing.
• Such a process requires the manufacture of two different parts and therefore the use of two presses or at least two different tools.
• Such a phenomenon disturbs or even prevents the passage of waves through this room, especially when the room is used as a protection device of a vehicle radar, also called a radome.
• a radome thus obtained imposes geometric constraints on the radar used, because the type of radar is limited by the size of the logo.
• the present invention is intended to overcome these disadvantages by providing an alternative manufacturing method of a plastic part, including a radome for a radar of a vehicle.
• the invention relates to a method of manufacturing a radome for a vehicle radar made of two thermoplastic materials and provided with a film, using a mold comprising a first part and a second part, the two parts delimiting a first molding chamber, the method comprising the following steps:
• thermoplastic material into the second molding chamber to obtain a second layer overmolded on the film, the film being positioned between the first and second overmolded layers.
• the first part may correspond to the matrix of the mold and the second part may correspond to a punch having means for ejecting the first overmolded layer after the injection of the first thermoplastic material into the first molding chamber.
• the third part may correspond to a second punch having different characteristics of the punch used for the first molding chamber.
• the first layer is overmolded on one side of the film and remains on the first part of the mold while the other side of the film is exposed to the open air in order to receive the injection of the second thermoplastic material once the second molding chamber is closed.
• the film remains positioned in the mold during the injection of the second thermoplastic material. No manipulation of the film is necessary which avoids damage to the film.
• thermoplastic material is added to the previously molded piece injection material which provides a good seal between the two layers while avoiding air bubbles or impurities that may be there in a manufacturing process requiring a gluing step.
• the method may further comprise one or more of the following features, taken alone or in combination:
• the method comprises a step of changing the position of the first part prior to the second closing of the mold.
• the change of position of the first part frees the space near the second part so that a new film can be placed on the wall of the second part for overmolding the next part.
• the step of changing the position of the first part is a step of rotation of the first part, so as to position itself vis-à-vis the third part.
• overmoulding can be performed using a plate or a rotary base.
• the punches are positioned around the axis of the plate or the base.
• the position change step of the first part is a translational step of the first part, so as to position vis-à-vis the third part.
• the overmoulding can be achieved with the aid of a carriage moving on the plate of the press.
• the punches are positioned on according to the trajectory of this carriage.
• the first thermoplastic material is chosen from the following materials: polycarbonate (PC), polypropylene (PP), polymethyl methacrylate (PMMA), polyamide (PA) or copolyester, such as polyethylene terephthalate (PET).
• PC polycarbonate
• PP polypropylene
• PMMA polymethyl methacrylate
• PA polyamide
• PET copolyester
• the second thermoplastic material is selected from the materials of the first thermoplastic material or in the following materials, preferably black: acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polypropylene (PP).
• ABS acrylonitrile butadiene styrene
• PC polycarbonate
• PP polypropylene
• the choice of the materials used for each injection makes it possible to obtain a first transparent or translucent layer and a second opaque layer.
• the film comprises a decorated surface and preferably metallized.
• the metallized surface having a chrome appearance can meet the aesthetic needs of the molded part depending on the vehicle model.
• the metallized surface is overmolded by the first thermoplastic material which is preferably transparent.
• the opposite surface of the film is overmolded by the second thermoplastic material which is preferably opaque.
• the decorated part of the film is therefore located between the film and the first thermoplastic material. This makes it possible to obtain a piece having a better gloss and a better sharpness of the metallic design. This is particularly advantageous when you want a depth effect in three dimensions for the decor, as is often the case for metallized logos. This configuration also makes it possible not to show the interface between the film and the decorated area because this interface area which is perhaps less aesthetic is hidden by the decoration.
• This metallized surface which is a functional surface of the film is rapidly protected as soon as the first thermoplastic material is injected.
• the film is held on all its surfaces on the first layer which allows to inject the second thermoplastic material whose thickness could even be larger and possibly with greater risks of deformation of the film if this second material was injected first.
• the method makes it possible to overmold a decorated film over a large area, with a minimum of handling, since the film is positioned only at the bottom of the impression by an operator or in an automated manner and, at the end of the various injection steps without leaving of the press, the final piece is obtained reproducibly and at a very high rate, with a film completely protected on both sides, with an interface without air bubble, a constant thickness over the entire surface serving as a radome, so to have good transparency on the airwaves.
• the metallized surface is obtained by a method of depositing a material, preferably by a vapor phase deposition technique, or by a painting process, or by overmolding a metallized film or by a marking technique hot.
• a material preferably by a vapor phase deposition technique, or by a painting process, or by overmolding a metallized film or by a marking technique hot.
• the use of this type of coating allows the passage of radar waves to provide detection functions in the development of vehicles partially or fully autonomous.
• the film has a good compatibility with the first and the second thermoplastic material so that the interface is of good quality (without bubble of air, without deformation of the film ...) so that the transparency with the waves is the best possible and this reproducibly even on a film of a large area.
• the method comprises a step of thermoforming the film prior to the step of closing the first molding chamber. It is a question of bringing a 3D form before the injection of the first plastic material.
• the film is therefore well deployed and homogeneous in thickness which limits the risk of deformation and even rupture during the injection process.
• the method comprises a step of cutting the film following the step of thermoforming the film.
• This configuration makes it possible to avoid the delamination of the final piece, which is all the more risky because the surface of the overmolded film is large. This delamination deteriorated the aesthetics of the room and hindered the passage of waves. The risk of entry of air or water between the two overmolded layers is also limited which prevents the aging of the room.
• the film includes a heating element.
• the heating element makes it possible to add a defrosting function to the overmolded part.
• the heating element may be a wire integrated directly into the film or a pattern of heating material. This pattern can be deposited on the film according to a method selected from the group consisting of screen printing, stencil, gravure printing, stamp printing, flexographic printing, offset printing, electrostatic printing and printing. inkjet printing.
• the heating element is arranged on the surface of the film between the film and the second overmolded layer. This arrangement makes it possible to have a "heat shield" effect thanks to the second material since the heat is transmitted preferentially towards the outside of the part, through the first material which will advantageously have a better thermal conductivity and may have a lower thickness. than the second matter.
• the film can be decorated or functionalized on both sides.
• Such a film is very fragile and must be handled with care so as not to deteriorate the decoration or functionalization.
• the manufacturing method which is the subject of this invention makes it possible not to manipulate the film between the different injection stages and thus to avoid the risk of damage.
• the invention also relates to a part, preferably for vehicle, obtained by the manufacturing method as described above.
• This piece may be a large piece, such as a motor vehicle grille whose dimensions of the front face may be 500 mm by 1200 mm.
• This piece can also be a bumper skin whose front dimensions can be 800 mm over 2000 mm.
• the invention also relates to a set of a vehicle radar and a part obtained by the manufacturing method as described above.
• the invention finally relates to a vehicle equipped with a set as described above.
• FIG. 1 is a schematic view of an example of a part manufacturing process during the injection of the first thermoplastic material
• FIG. 2 is a schematic view of the process according to FIG. 1 during the injection of the second thermoplastic material
• FIG. 3 is a schematic view of a first embodiment of the part comprising a heating element
• FIG. 4 is a schematic view of the manufacturing process of the part according to FIG. 3,
• FIG. 5 is a schematic view of a second embodiment of the part comprising a heating element
• FIG. 6 is a detailed view of the part obtained by the manufacturing method according to a first variant
• FIG. 7 is a detailed view of the part obtained by the manufacturing method according to a second variant.
• a mold as schematically illustrated in Figure 1 comprises a first portion 10 and a second portion 20, the two parts 10, 20 defining a first molding chamber 100.
• the first part 10 of the mold is mounted on a plate or a rotary base of an axis (A).
• a film 3 is placed on an inner wall 21 of the second part 20.
• This technology makes it possible to integrate all kinds of functions (electronics, mechanics, optics ... and more particularly here functional elements for the defrost, the light or the electrical connection) directly on the plastic parts, here a flexible polymer substrate.
• the functionalized part can then be deformed.
• the materials usually used are polyimide (PI), polyetheretherketone (PEEK), PolyEthylene Naphthalate (PEN) and other materials may be envisaged.
• this film has at least one decorated face, preferably metallized with a chrome appearance.
• the metallized surface is obtained by a method of depositing a material, preferably of indium type, or by a painting process, or by overmolding a metallized film.
• the decorative coating, and especially the metallized surface is obtained by a technique known to those skilled in the art, such as the hot stamping technique (printing during which a film is pressed against a surface), or via overmoulding of a metallized film (for example by the preliminary deposition of a thin layer of coating which gives a metallic appearance, layer of the order of 0.5 ⁇ ), or by application of chromatic paint, or by the technique of physical vapor deposition (PVD), metals such as indium, gold or tin.
• PVD physical vapor deposition
• first thermoplastic material is injected into the first molding chamber 100 to obtain a first overmolded layer 1 on the film 3.
• the first thermoplastic material is chosen from the following materials: polycarbonate (PC), polypropylene (PP), polymethylmethacrylate (PMMA), polyamide (PA) or copolyester, such as polyethylene terephthalate (PET).
• first thermoplastic material is transparent in color. It is important to put the film on the second part 20 with the opposite side to that which is metallized in contact with the inner wall 21. Thus, the first thermoplastic material is overmolded on this metallized face, which makes it possible to obtain a part having a better gloss and a better sharpness of the metallized design.
• the mold is opened to separate the first portion 10 and the second portion 20. Simultaneously, the first overmolded layer 1 is repelled by ejection means which are arranged in the second portion 20. The first overmolded layer 1 and remains fixed on the first portion 10 during the opening of the mold.
• the first part 10 changes position by turning about the axis (A) so as to be positioned vis-à-vis a third part 30
• the mold is closed so as to form a second molding chamber 200 which is delimited by the first portion 10 and the third portion 30.
• This step is followed by an injection of a second thermoplastic material into the second chamber molding material 200 to obtain a second overmolded layer 2 on the film 3.
• the second thermoplastic material is chosen from the following materials: acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polypropylene (PP), polymethyl methacrylate (PMMA), polyamide (PA) or copolyester, such as polyethylene terephthalate (PET).
• the second thermoplastic material is black in color and is injected onto the film of the opposite side to that which is metallized.
• the film 3 is positioned between the first and second overmolded layers 1, 2.
• the method may comprise a step of thermoforming the film prior to the step of closing the first molding chamber 100. A 3D shape can therefore be provided to the metallized face of the film before the injection of the first plastic material.
• the method comprises a step of cutting the film 3 following the thermoforming step of the film 3.
• the film 3 no longer spreads over the final piece but is only present on a predefined area of the room.
• the first variant illustrated in Figure 6 consists of an injection of the first thermoplastic material by creating a projecting zone 5 at the edge of the film.
• the second overmolded layer 2 takes a shape complementary to that of the first overmolded layer 1, which allows the film 3 to be well trapped between the two layers without having any space around it.
• the second variant illustrated in Figure 7 consists of an injection of the first thermoplastic material by creating a groove 6 between the film 3 and the mold.
• the second overmolded layer 2 takes on a shape complementary to that of the first overmolded layer 1. Because the film 3 is at the edge of the molding tool, so at the bottom of a housing, it is easier to position it and hold it in place.
• the film 3 comprises a heating element 31 connected to a power supply wire 32.
• the heating element 31 is arranged between the film 3 and the second overmolded layer 2.
• FIG. a first embodiment as illustrated in Figures 3 and 4, an insert can be used in the mold to create a passage 4 of the power supply wire 32 in the second overmolded layer 2.
• This embodiment allows to pass the power supply wire 32 on the non-visible side of the final part and to avoid problems of integration of the part on the vehicle.
• a second embodiment can also be envisaged according to which the electric power wire is in part between the two overmolded layers, as can be seen in FIG. 5.
• the invention is not limited to the embodiments presented and other embodiments will become apparent to those skilled in the art. It is in particular possible to change the position of the first part of the mold by a translation movement of this first part 10, so that it is positioned vis-à-vis the third part 30.
• the method comprises a step of injecting a third plastic material via a third punch and overmolding a second film during this additional step.
• the second film is positioned in the impression of the third punch and the piece resulting from the two preceding injections is placed in front of this punch, while preserving a volume in which the third plastic material is injected.
• a film with heating elements or a decorated film and the second film is a decorated film.
• the first plastic and the second plastic are opaque materials which are on each side of the first film.
• the second film can be a decorated film If the second film is positioned on the piece resulting from the two previous injections before injection of the third material, then this third material advantageously covers the second film.
• the film can hold in the bottom of the footprint by electro-droop or a suction system on the surface of the footprint can be considered to position it properly and hold it in place during the injection of the plastic material. If the second film is positioned on the part resulting from the two previous injections, then an equivalent system to hold the film in place can be considered across the room.

Landscapes

• Engineering & Computer Science (AREA)
• Radar, Positioning & Navigation (AREA)
• Remote Sensing (AREA)
• Physics & Mathematics (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Computer Networks & Wireless Communication (AREA)
• General Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Injection Moulding Of Plastics Or The Like (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=60450806

Family Applications (1)

Country Status (4)

Families Citing this family (5)

Family Cites Families (7)

• 2017
  • 2017-09-01 FR FR1758072A patent/FR3070618B1/fr not_active Expired - Fee Related
• 2018
  • 2018-08-31 EP EP18759337.1A patent/EP3676070A1/de not_active Withdrawn
  • 2018-08-31 WO PCT/EP2018/073546 patent/WO2019043202A1/fr unknown
  • 2018-08-31 CN CN201880055324.1A patent/CN111093934A/zh active Pending

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