JP2010111011A - Radio wave transmission cover for vehicle and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To align a first design and a second design with high accuracy. <P>SOLUTION: When a rugged shape 304 becoming the second design is formed on a film 250, it is not necessary to consider the alignment of the second design with the first design. The alignment accuracy of a black resin layer 350 being the first design with the rugged shape 304 being the second design depends on molding accuracy. Therefore, the black resin layer (the first design) 350 is easily aligned with the rugged shape (the second design) 304 in high accuracy. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a vehicle radio wave transmission cover, particularly a vehicle radio wave transmission cover and a vehicle electromagnetic transmission cover arranged in a path of a radar wave emitted from a radio wave radar device such as a millimeter wave radar device or a microwave radar device. It relates to a manufacturing method.

  An automobile front grill is often provided with an emblem part having a predetermined design shape.

In recent years, a radio wave radar device (for example, a millimeter wave radar device or a microwave radar device) may be provided on the rear side of the front grill for the purpose of measuring the distance between vehicles or the distance to an obstacle. Therefore, emblem parts (vehicle radio wave transmission covers) that are arranged in the path of the radar wave emitted from the radio wave radar device and transmit the radar wave have been proposed (see, for example, Patent Document 1 and Patent Document 2).
JP 2004-251868 A JP 2007-13722 A

  Here, in patent document 1 and patent document 2, while the 1st design is printed, the 2nd design is expressed by uneven | corrugated shape.

  Therefore, it is necessary to perform alignment with high accuracy so that a positional shift does not occur between the printed first design and the second design having an uneven shape.

  In particular, when the first design is white print, and the first design and the second design that form an uneven shape in the white portion are continuous (when the parting lines are in contact with each other) ) If the design parting between the first design and the second design is misaligned, there will be a gap or overlap at the boundary between the first design and the second design. Is great). Therefore, it is necessary to accurately match the print parting and the concavo-convex shape, and it is necessary to perform alignment with higher accuracy (more improvement in design parting quality is required).

  In consideration of the above, the present invention is a vehicle radio wave transmission cover in which the first design and the second design are aligned with high accuracy, and the first design and the second design are aligned with high accuracy. It is an object to provide a method for manufacturing a radio wave transmission cover for a vehicle that can be used.

  According to the first aspect of the present invention, the transparent resin layer constitutes the outer surface and has a recess for forming the first design and a recess for forming the second design on the back surface opposite to the outer surface. A transparent resin layer molding step, a colored resin molding step of molding a colored resin layer in the concave portion forming the first design of the transparent resin layer, and the transparent resin layer and the colored resin layer in the transparent resin layer. A film layer forming step of forming a film layer by laminating a film having an uneven shape corresponding to the recess forming the second design of the resin layer, and a base material for forming the base material layer on the film layer And a layer forming step.

  Therefore, it is not necessary to consider the alignment with the first design when shaping the uneven shape to be the second design on the film. The first design, the second design, and the positional accuracy are substantially determined by the molding accuracy of the transparent resin layer. Generally, since the molding accuracy is high, the first design and the second design are easily aligned with high accuracy (the first design and the second design are easily misaligned. Is prevented or suppressed).

  In particular, when the first design (colored resin layer) and the second design (uneven shape) are continuous (when the parting lines touch each other), the parting line of the first design (colored resin layer) And the parting line of the second design (uneven shape) are aligned with high precision (parting lines substantially coincide). That is, the design parting quality is improved.

  According to a second aspect of the present invention, in the method of manufacturing a radio wave transmission cover for a vehicle according to the first aspect, in the film layer forming step, a film formed into a final outer shape is bonded.

  Therefore, it is not necessary to cut the whole (cut unnecessary portions) and form the final outer shape after forming the base material layer. Therefore, manufacture is easy and as a result, the manufacturing cost of the vehicle radio wave transmission cover is effectively reduced.

  According to a second aspect of the present invention, in the vehicle radio wave transmission cover manufacturing method according to the first or second aspect, a metal film is deposited on the film.

  Therefore, metallic luster is obtained, and as a result, a high-class feeling is obtained, for example.

  The invention of claim 4 constitutes an outer surface and a transparent resin layer provided with a recess for forming a first design and a recess for forming a second design on the back surface opposite to the outer surface; A base material layer disposed opposite to the back surface opposite to the outer surface, and provided with a convex portion that forms the second design on the surface facing the back surface, and the first of the transparent resin layer Provided in the concave portion forming the design, and disposed between the colored resin layer constituting the first design, the transparent resin layer and the base material layer, and the concave portion and the base of the transparent resin layer It is made into the uneven | corrugated shape formed with the said convex part of a material layer, and has the film layer which comprises said 2nd design, It is characterized by the above-mentioned.

  Therefore, the first design, the second design, and the positional accuracy are substantially determined by the molding accuracy. That is, the first design and the second design are aligned with high accuracy. In particular, when the first design (colored resin layer) and the second design (uneven shape) are continuous, the design parting quality between the first design and the second design is improved.

  According to a fifth aspect of the present invention, in the method for manufacturing a radio wave transmission cover for a vehicle according to the forty-second aspect, a metal film is deposited on the film.

  Therefore, metallic luster is obtained, and as a result, a high-class feeling is obtained, for example.

  According to the method for manufacturing a radio wave transmission cover according to claim 1, the first design and the second design can be aligned with high accuracy.

  According to the method for manufacturing the radio wave transmission cover according to claim 2, the manufacturing cost can be effectively reduced.

  According to the method for manufacturing a radio wave transmission cover according to claim 3, a metallic luster can be obtained, and as a result, for example, a high-class feeling can be obtained.

  According to the radio wave transmission cover of the fourth aspect, the first design and the second design are aligned with high accuracy.

  According to the radio wave transmitting cover of the fifth aspect of the invention, a metallic luster can be obtained, and as a result, a high-class feeling can be obtained, for example.

  Hereinafter, a method for manufacturing a radio wave transmission cover for a vehicle according to an embodiment of the present invention will be described with reference to the drawings. In the present embodiment, the millimeter wave radar (radar wave) that is attached to the front end of the vehicle and is emitted from the millimeter wave radar device (radio wave radar device) mounted on the front of the vehicle is arranged. The present invention is applied to a wave radar cover (vehicle radio wave transmission cover).

  First, a millimeter wave radar cover (vehicle radio wave transmission cover) will be described with reference to FIGS. In addition, arrow UP in a figure shows a vehicle up direction, arrow FR shows a vehicle front direction, and arrow OUT shows a vehicle width direction outer side direction.

  FIG. 1 is a perspective view showing a vehicle in which a millimeter wave radar cover according to an embodiment of the present invention is attached to a front end portion. FIG. 2 is a horizontal cross-sectional view schematically showing the vicinity of a part to which a millimeter wave radar cover is attached at the front of the vehicle. 3A is a partial cross-sectional perspective view showing the millimeter wave radar cover, and FIG. 3B is an enlarged cross-sectional view of a portion surrounded by B in FIG.

  As shown in FIG. 1, a millimeter wave radar cover (emblem part) 100 as a vehicle radio wave cover 100 is attached to an opening 14 at the center of a front grill 12 at the front end of a vehicle 10 (also in FIG. 2). reference). The millimeter wave radar cover 100 is formed with an emblem such as a company symbol mark.

  As shown in FIG. 2, the millimeter wave radar cover 100 is disposed on a path of the millimeter wave radar L on the vehicle front side of the millimeter wave radar device 20 as a radio wave radar device mounted on the front portion of the vehicle. In FIG. 2, the cross section of the millimeter wave radar cover 100 is not shown.

  The millimeter wave radar device 20 is provided to emit the millimeter wave radar L toward the front of the vehicle and measure the distance of a vehicle, an obstacle, or the like in front of the vehicle.

  As shown in FIG. 3A, the overall shape of the millimeter wave radar cover 100 is a plate shape having a substantially elliptical shape when viewed from the front (see also FIGS. 1 and 2). 3A and 3B, the millimeter wave radar cover 100 has a four-layer structure of a transparent resin layer 200, a black resin layer 350, a decorative layer 300, and a base material layer 400. It is said that.

  The millimeter wave radar cover 100 has a transparent resin layer 200 (outer surface 200A) on the vehicle outer side (vehicle front side), that is, the front surface (front surface), and the vehicle inner side (vehicle rear side), that is, the rear surface. The base material layer 400 is used. The outer surfaces of the transparent resin layer 200 and the base material layer 400 (both surfaces of the millimeter wave radar cover 100) are substantially smooth, and the radar waves emitted from the millimeter wave radar device 20 (see FIG. 2). L (see FIG. 2) has a surface shape that allows easy transmission.

  In the present embodiment, the transparent resin layer 200 is made of a transparent acrylic resin, and the base material layer 400 is made of an AES resin (Acrylonitrile-Ethylene-Styrene resin, acrylonitrile ethylene propylene diene styrene copolymer). In addition, you may shape | mold with resin other than these. For example, ABS resin or polycarbonate resin may be used.

  In the present embodiment, the decorative layer 300 is configured by a transparent PET resin film 250 (see FIG. 4), and has a concavo-convex shape (concavo-convex design) 304 forming a second design (concavo-convex shape). The second design (uneven design) is expressed by forming 304). Further, a metal film such as indium is deposited on the entire back surface of the decorative layer 300 (film 250) so that a metallic luster is obtained.

  Moreover, the black resin layer 350 is comprised by the black acrylic resin, and except the convex part which became convex toward the transparent resin layer 200 side of the uneven | corrugated shape 304 in the surface of the decorating layer 300 (film 250). It is formed in the part and constitutes the first design.

  Therefore, when the millimeter wave radar cover 100 is viewed from the front, the portion other than the convex shape (second design) is black (first design) (see FIG. 3A).

  Next, a manufacturing method of the millimeter wave radar cover 100 will be described with reference to FIGS. FIG. 4A is a process diagram illustrating, in order, steps (A) to (B), in which the film 250 is vacuum-formed and the uneven shape 304 forming the second design is formed. FIG. 5A is a plan view showing the film 250 after being vacuum-formed, and FIG. 5B is a plan view showing a decorative layer (decorative body) 300 formed by trimming to the final outer shape. is there. In other words, it is a process diagram showing the trimming process in order from (A) to (B). FIG. 6 is a process diagram showing the steps of manufacturing the millimeter wave radar cover 100 by injection molding in order from (A) to (I). FIG. 7 is a cross-sectional view schematically showing the transparent resin layer 200.

  First, the process of manufacturing the decorative layer (decorative body) 300 will be described.

  As shown in FIG. 4A, a PET film 250 having a metal film such as indium deposited on the back surface is attached to vacuum molds 262 and 264 so that a metallic luster is obtained. As shown in FIG. 4, the uneven shape 304 is shaped (vacuum forming) by the vacuum forming apparatus 240.

  Then, as shown in FIG. 5A, the film 250 on which the concavo-convex shape 304 is formed is unnecessary so as to have the final outer shape (the outer shape shown in FIG. 3) as shown in FIG. The decorative layer 300 is formed by trimming and trimming the shape.

  The film 250 can be made of a general resin material such as PMMA or polyamide in addition to the PET resin. Also, the metal material can be deposited by a general deposition method such as vacuum deposition. Note that the metal film is not necessarily deposited (the metal film is not necessarily deposited).

  Moreover, the uneven shape 304 may be shaped by other forming methods such as pressure forming and press forming, instead of vacuum forming as in the present embodiment.

  Next, a process for manufacturing the millimeter wave radar cover 100 will be described.

  As shown in FIG. 6A, the transparent resin layer 200 is formed by the injection molds 222 and 224 of the injection molding apparatus 280. At this time, as schematically shown in FIG. 7, a recess in which a black resin layer (first design) 350 (see FIG. 3) is formed on the back surface 200 </ b> B opposite to the outer surface 200 </ b> A of the transparent resin layer 200. 202 and the recessed part 204 in which the uneven | corrugated shape (2nd design) 304 (refer FIG. 3) is formed are formed.

  Next, as shown in FIG. 6B, the rear mold is replaced with an injection mold 226, and a black resin layer 350 is formed in the recess 202 (see FIG. 7). That is, two-color molding is performed using a transparent resin and a black resin.

  Next, as shown in FIG. 6-1 (C), the concave and convex shapes 304 of the decorative layer 300 are fitted into the concave portions 204 and bonded together, and the molding die on the back side is replaced with an injection molding die 228.

  Then, as shown in FIGS. 6-2 (D) and 6-2 (E), the base material layer 400 is injection-molded on the back surface of the decorative layer 300. Thereby, the convex part 402 is formed in the base material layer 400 by filling the base material layer 400 in the concave part of the decorative layer 300 corresponding to the concave part 204 of the transparent resin layer 200. Further, the millimeter wave radar cover 100 is taken out from the mold, and finishing such as cutting of the gate 190 and deburring is performed.

  Thereafter, as shown in FIG. 6B, the millimeter wave radar cover 100 is annealed, that is, heated to remove internal stress. As shown in FIGS. 6 (H) and 6 (I), if the inspection such as millimeter wave attenuation measurement shown in FIG. After entering a history (traceability) such as a serial number in 100, bagging and boxing are performed.

  Next, the operation of this embodiment will be described.

  The positional accuracy between the first design black resin layer 350 and the second design uneven shape 304 is substantially determined by the molding accuracy of the transparent resin layer 200. In general, since the molding accuracy is high, the black resin layer (first design) 350 and the concavo-convex shape (second design) 304 are aligned with high accuracy (black resin layer (first design)). ) And the uneven shape (second design) 304 are easily prevented or suppressed.

  In particular, as in the present embodiment, when the black resin layer (first design) 350 and the concavo-convex shape (second design) 304 are continuous (when the parting lines are in contact with each other), the black resin layer The parting part M (see FIG. 3) between the (first design) 350 and the uneven shape (second design) 304 is matched with high accuracy.

  In other words, deterioration in design parting quality due to gaps or overlaps in the parting part (boundary part) M between the black resin layer (first design) 350 and the concavo-convex shape (second design) 304 is prevented or It is suppressed. That is, the parting line of the black resin layer (first design) 350 and the parting line of the concavo-convex shape (second design) 304 substantially coincide with each other, so that the black resin layer (first design) 350 and the concavo-convex shape (second design) Design cut quality with 304 is improved.

  Here, as shown in FIG. 9A, a design corresponding to the black resin layer 350 is printed, and mounted on the vacuum forming molds 262 and 264 in accordance with the white portions 302 of the printing, and FIG. ), When the uneven shape 304 is formed by vacuum forming, it is necessary to perform high-precision alignment and vacuum forming so as not to cause misalignment between the white portion 302 of the print and the uneven shape. In other words, it is necessary to align the film 250 with high accuracy and attach it to the molding die so that a positional shift does not occur between the printed first design and the uneven shape.

  However, in this embodiment, it is not necessary to consider the alignment with the first design when forming the uneven shape 304 as the second design on the film 250.

  Thus, according to the manufacturing method of the present embodiment, the black resin layer (first design) 350 and the uneven shape (second design) 304 are easily aligned with high accuracy. In addition, a design that is more complicated than the design of either one of the black resin layer (first design) 350 and the uneven shape (second design) 304 is obtained.

  Moreover, as shown in FIG. 5, since the film 250 is trimmed to the final outer shape to form the decorative layer (decorative body) 300, it is not necessary to trim to the final outer shape after the injection molding. Therefore, the manufacturing is easy, and as a result, the manufacturing cost is effectively reduced. Further, the product outer peripheral surface of the millimeter wave radar cover 100 can be finished more beautifully.

  In addition, since a metal film is deposited on the film 250 (decorative layer 300), a metallic luster is obtained in the millimeter wave radar cover 100, and as a result, a high-class feeling is obtained.

  Further, by forming the uneven shape 304 on the decorative layer (decorative body) 300, a deep engraving design can be easily realized.

  In addition, in the said embodiment, although manufactured using the decorating layer (decorative body) 300 which made the film 250 the final external shape, it is not limited to this. After the base material layer 400 is injection-molded (FIG. 6-2 (E)), it may be trimmed to the final outer shape.

  Moreover, although the black resin layer 350 is formed in parts other than the convex part which became convex toward the transparent resin layer 200 side of the uneven | corrugated shape 304, it is not limited to this. The first design may have any shape. For example, as shown in FIG. 8, a recess 206 corresponding to the first design may be formed on the back surface 200B of the transparent resin layer 200. Further, the black resin layer 350 may have a color other than black.

  Moreover, unless the effect by this invention is prevented, you may include processes other than the said process.

  Further, for example, a radio wave radar device other than the millimeter wave radar device 20 (see FIG. 2), for example, a microwave radar device may be used.

  The embodiments of the present invention have been described with reference to the embodiments. However, the above embodiments are merely examples, and various modifications can be made without departing from the scope of the invention. Further, it goes without saying that the scope of rights of the present invention is not limited to the above-described embodiment, and can be implemented in various modes without departing from the gist of the present invention.

1 is a perspective view showing a vehicle in which a millimeter wave radar cover according to an embodiment of the present invention is attached to a front end portion. FIG. 3 is a horizontal cross-sectional view schematically showing the vicinity of a part where a millimeter wave radar cover is attached in the front part of the vehicle. (A) is a partial cross-sectional perspective view showing a millimeter wave radar cover, and (B) is an enlarged cross-sectional view of a portion surrounded by B in (A). (A) is process drawing which shows the process of vacuum-forming a film and shaping the uneven | corrugated shape which forms a 2nd design to (A)-(B) in order. (A) is a top view which shows after a film is vacuum-formed, (B) is a top view which shows the decorating layer (decorative body) formed by trimming to the final external shape. It is process drawing which shows (A)-(C) of the process of manufacturing the cover for millimeter wave radars by injection molding. It is process drawing which shows (D)-(I) of the process of manufacturing the cover for millimeter wave radars by injection molding. It is sectional drawing which shows a transparent resin layer typically. It is sectional drawing which shows typically the transparent resin layer in case the black resin layer of another design is formed. It is process drawing which shows in order to (A)-(C) the process of vacuum-forming, after forming the design corresponding to a black resin layer, and shaping an uneven | corrugated shape, without applying this invention.

Explanation of symbols

10 Vehicle 20 Millimeter wave radar device (Radio wave radar device)
100 Millimeter wave radar cover (radio wave transmission cover)
DESCRIPTION OF SYMBOLS 200 Transparent resin layer 200A Outer surface 200B Back surface 202 The recessed part which forms the 1st design 204 The recessed part which forms the 2nd design 250 Film 300 Decorating layer (film layer)
304 Concavity and convexity 350 Colored resin layer 400 Base material layer 402 Convex part forming the second design
L Radar wave

Claims (5)

Transparent resin layer molding which forms an outer surface and forms a transparent resin layer so that a concave portion forming a first design and a concave portion forming a second design are formed on the back surface opposite to the outer surface. Process,
A colored resin molding step of molding a colored resin layer in a recess forming the first design of the transparent resin layer;
A film layer forming step of forming a film layer by laminating a film formed with a concavo-convex shape corresponding to a concave portion forming the second design of the transparent resin layer on the transparent resin layer and the colored resin layer; ,
A base layer forming step for forming a base layer on the film layer;
A method for manufacturing a radio wave transmission cover for a vehicle, comprising:   The method for manufacturing a radio wave transmission cover for a vehicle according to claim 1, wherein in the film layer forming step, a film formed into a final outer shape is bonded.   The method for manufacturing a radio wave transmission cover for a vehicle according to claim 1 or 2, wherein a metal film is deposited on the film. A transparent resin layer comprising an outer surface and a recess that forms a first design and a recess that forms a second design on the back surface opposite to the outer surface;
A base material layer disposed opposite to the back surface opposite to the outer surface and provided with a convex portion forming the second design on the surface facing the back surface;
A colored resin layer provided in a concave portion forming the first design of the transparent resin layer, and constituting the first design;
It is arranged between the transparent resin layer and the base material layer, and has an uneven shape formed by the concave portion of the transparent resin layer and the convex portion of the base material layer, and the second design A film layer comprising;
A radio wave transmission cover for a vehicle, comprising:   The vehicle radio wave transmission cover according to claim 4, wherein a metal film is deposited on the film.

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