JP2010216924A - Decorative member, radar unit and method for producing decorative member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To constitute a molded product that has metallic appearance, does not suppress the passage of an electromagnetic wave of a specific frequency, and has excellent design by coating the surface with a synthetic resin. <P>SOLUTION: A base material 16 is three-dimensionally processed and sandwiched between a front face material 12 and a back face material 14. A projecting part of the base material 16 is metallic and a recessed part is provided with a black printed layer 24. The front face material 12 side of a decorative member 10 plays a decorative role, and on the back face thereof, an electromagnetic wave transceiver is suitably disposed. An electromagnetic wave transmitted from or received by the electromagnetic wave transceiver is a millimeter wave (about 4 mm), and an attenuation rate when the millimeter wave passes varies with the thickness of the base material 16 (total reflection sheet 22) applied to the decorative member 10. The attenuation rate varies based on the material. When the upper limit value of the attenuation rate (dB) of the millimeter wave is set to 2 dB and the thickness of the decorative member 10 is about 5 to 8 mm, the base material is preferably formed of polycarbonate, and has a thickness of 7.2±0.2 mm or 6.0±0.2 mm. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a decorative member using a total reflection sheet, a radar unit including the decorative member and a distance detecting radar, and a decorative member manufacturing method.

  Conventionally, a metallic appearance is often applied to a decorative member of a vehicle. For example, a metallic tone is required for a molded product such as a louver constituting a front grille of a vehicle, a vehicle attached to the center of the front grille, or an emblem for identifying a vehicle name.

  As a means for imparting a metallic tone to such a molded article, it is common to apply a paint containing metal particles or to form a metal film by plating or vapor deposition.

  Here, in recent years, a radar unit may be mounted on a vehicle in order to quickly recognize an obstacle ahead. The radar unit includes a radio wave transmitter and a receiver, and determines the presence or absence of an obstacle by measuring the time until the radio wave emitted from the transmitter bounces off the obstacle and is received by the receiver.

  In such a radar unit, when there is a continuous metal film (metal layer) in a radio wave transmission area, an electromagnetic wave shielding property is generated and a radio wave interference is generated. The radio wave interference is a function that impairs the function of the radar unit, such as the radio wave transmitted from the transmission unit does not reach the front of the vehicle or the radio wave reflected from the obstacle cannot be received by the reception unit. Since the radar unit is concealed from the outside, the radar unit is preferably arranged on the back side of the decorative member.

  On the other hand, as described above, the decorative member of the vehicle is required to be processed in a metallic manner, and has a trade-off relationship depending on the relative position of the radar unit and the decorative member.

  Here, in patent document 1, the film which permeate | transmits electromagnetic waves and maintains a natural metallic tone with high brightness is proposed.

  More specifically, the film of Patent Document 1 is a laminated film in which at least two or more types of plastic resin layers are alternately laminated in the thickness direction, and the reflectance at a wavelength of 400 nm to 1000 nm is 30% or more. In a tensile test at 150 ° C., the number of layers having a tensile strength of 3 MPa to 90 MPa and a layer thickness of 10 nm to less than 220 nm in a film longitudinal direction and a width direction of 100% elongation is 220 nm to 320 nm. More than the number, the laminated film contains at least one ultraviolet absorber selected from a malonic acid ester compound or an oxalic acid anilide compound.

  As a reference, Patent Document 2 discloses an automobile emblem (decorative member) that is configured to have radar total transparency and that does not adversely affect radar propagation due to diffraction, refraction, scattering, and reflection.

  The emblem has a metallic glossy layer that completely reflects electromagnetic radiation or light within the visible wavelength range and transmits the longer wavelength radar waves with little attenuation. Is described as thin. Patent Document 2 also describes that coating with a metallic non-metallic special paint is possible.

JP 2008-200701 A JP 2000-49522 A

  However, the film of Patent Document 1 has a metallic appearance and transmits electromagnetic waves. For example, as a decorative member such as a vehicle emblem, a part of the film is printed, or the periphery is formed by injection molding or the like. When a molded product covered with is produced, the adhesion between the injected synthetic resin and the film is lacking, and the design is impaired.

  Further, in Patent Document 2, when a metal film layer is used, the film thickness is limited, and the design freedom is restricted. It should be noted that the metallic glossy non-metallic special paint is not specifically shown or suggested.

  In consideration of the above facts, the present invention can form a molded article that has a metallic appearance, does not suppress the passage of electromagnetic waves of a specific frequency such as millimeter waves, and is excellent in design. It is an object to obtain a decorative member, a radar unit, and a decorative member manufacturing method.

  According to the first aspect of the present invention, there is provided a printed layer in which a pattern is printed on at least one surface of a total reflection sheet that totally reflects light by laminating a film layer of polyethylene resin that does not transmit light in different frequency bands. A decorative member formed by setting the provided base material in a predetermined mold and injecting synthetic resin into the front and back surfaces of the base material, and providing an adhesive layer on the front and back surfaces of the base material The decorative member is characterized in that it is dissolved at the time of injecting the synthetic resin so that the substrate and the synthetic resin are brought into close contact with each other.

  According to 1st invention, a base material becomes a mirror surface sheet for totally reflecting light, and can obtain a metallic tone. However, it does not suppress the passage of predetermined electromagnetic waves. Further, by providing the adhesive layer, the base material and the synthetic resin are in close contact with each other, and a decorative member having excellent design properties can be obtained.

  1st invention WHEREIN: The said synthetic resin injection | pouring is injection | pouring by injection molding, The injection | pouring direction is a metal mold | die ceiling surface through the synthetic resin injection | pouring space on an adhesive layer, It is characterized by the above-mentioned.

  When the synthetic resin dissolved in the adhesive layer is directly sprayed, the temperature difference of the adhesive layer between the directly sprayed portion and the portion that is not sprayed becomes large, which may impair the adhesion. Therefore, the mold ceiling surface is used so that the synthetic resin to be injected is not directly sprayed onto the adhesive layer.

  In the first invention, the film layer is made of a polyethylene material, and an acrylic printing ink is applied to the printing. The acrylic printing ink also serves as an adhesive layer.

  When printing is performed, the printing ink for this printing is acrylic, so that the adhesiveness with the synthetic resin equivalent to the presence of the adhesive layer can be provided.

  Further, in the first invention, the film layer is a polyethylene-based material, and a film of the same system as the material to be injected on the front and back surfaces of the polyethylene-based resin laminated film is laminated, so that the laminate film is formed of the adhesive layer. It functions as an alternative.

  According to a second aspect of the invention, there is provided a distance detecting radar that measures the distance to a reflection target by outputting an electromagnetic wave in a predetermined direction and receiving a reflected wave of the output electromagnetic wave with the decorative member of the first aspect. And the decorative member is arranged at least on the electromagnetic wave output surface side of the distance detection radar and conceals the distance detection radar.

  According to the second aspect of the present invention, it is possible to hide the position detection radar from a position that is not visible from the outside without impairing the function of the distance detection radar.

  According to a third aspect of the present invention, a polyethylene resin film layer that does not transmit light in different frequency bands is laminated, whereby a total reflection sheet that totally reflects light is cut into a predetermined shape and subjected to predetermined printing. An adhesive layer is provided on the front and back surfaces of the base material, the base material with the adhesive layer is set in a surface molding die, and a synthetic resin is injected on the surface side to dissolve the adhesive layer, The material and the solidified synthetic resin are in close contact to form an assembly, the assembly is set in a back surface molding die, and the synthetic resin is injected on the back surface side. It is a decorative member manufacturing method produced | generated by melt | dissolving an adhesive layer and adhere | attaching the said base material and the said synthetic resin.

  According to 3rd invention, a base material becomes a mirror surface sheet | seat for totally reflecting light, and can obtain a metallic tone. That is, although it is metallic, it is not metal, it does not suppress the passage of predetermined electromagnetic waves. Further, by providing the adhesive layer, the base material and the synthetic resin are in close contact with each other, and a decorative member having excellent design properties can be obtained.

  As described above, according to the present invention, it is possible to form a molded product having a metallic appearance, without suppressing passage of electromagnetic waves having a specific frequency such as millimeter waves, and having excellent design. It has an excellent effect of being able to.

It is a perspective view of the decoration member concerning this embodiment. (A) is sectional drawing of the base material which concerns on this Embodiment, (B) It is sectional drawing of the decoration member by which the surface material and the back material were assembled | attached to the base material. The characteristics of the film layer used in the reflection sheet are shown. (A) is the wavelength-reflectance characteristic diagram of the film layer reflecting the low frequency in the visible wavelength, and (B) is the medium in the visible wavelength. FIG. 4C is a wavelength-reflectance characteristic diagram of a film layer reflecting a region, and FIG. 4C is a wavelength-reflectance characteristic diagram of a film layer reflecting a high region of visible wavelengths. It is a wavelength-reflectance characteristic figure by the difference in the number of film layers in a reflective sheet. It is a flowchart which shows the process of the manufacturing method of the decoration member which concerns on this Embodiment. It is a perspective view which shows the Example of the radar unit with which the decoration member which concerns on this Embodiment was applied to the vehicle. FIG. 7 is an enlarged front view of the radiator grill shown in FIG. 6. FIG. 7 is an enlarged side cross-sectional view of the radiator grill shown in FIG. 6.

  FIG. 1 shows a decorative member 10 according to the present embodiment.

  The decorative member 10 is roughly divided into a three-layer structure, the front surface side is formed of a transparent synthetic resin material (hereinafter referred to as “surface material 12”), and the back surface side is non-transparent (for example, black with AES or ABS) and the like (hereinafter, referred to as “back surface material 14”).

  The decorative member 10 has a dome shape in which the central portion protrudes most, and a base that is designed as a first function as the decorative member 10 is provided between the surface material 12 and the back surface material 14. A material 16 is sandwiched. In the middle of the manufacturing process of the decorative member 10 (hereinafter, detailed description), adhesive layers 18 and 20 (see FIG. 5) are provided on the front surface and the back surface of the base material 16, respectively. The adhesive layers 18 and 20 are dissolved and become transparent, and the base material 16 and the surface material 12 and the space between the base material 16 and the back material 14 are sealed.

  As shown in FIG. 2A, the base material 16 is applied with a total reflection sheet 22 as a material, and a printed layer 24 is provided on the surface (the surface facing the surface material 12).

  The total reflection sheet 22 is generated by laminating a film layer of polyethylene resin that does not transmit light in different frequency bands, and totally reflects light, that is, forms a mirror surface. The mirror surface is similar to the polished metal surface, and thus the total reflection sheet has a metallic tone. In other words, “metal tone” means that the finish is as if it is a metal without using any metal. For example, it does not suppress the passage of electromagnetic waves.

  FIG. 3 shows the characteristics of the total reflection sheet 22. For example, when a film layer having the wavelength-reflectance characteristics shown in FIGS. As described above, a sheet having a reflectance of about 70 to 80% can be formed.

  Further, when the layers are stacked to form 17 layers, a sheet having a reflectivity of about 90% can be formed as shown by an arrow B in FIG.

  In this embodiment, since it is required to have a mirror finish, as shown by an arrow C in FIG. 4, the film layer is set to 400 or 800 layers, and the reflectance is set to approximately 100%.

  A base material 16 shown in FIG. 2A is sandwiched between the surface material 12 and the back surface material 14 in a three-dimensionally processed state as shown in FIG. The 16 convex portions are metallic, and the black region of the print layer 24 is located in the concave portions.

  The decorative member 10 has a design role on the surface material 12 side, and an electromagnetic wave transmitter / receiver (for example, the millimeter wave radar 60 shown in FIG. 6) is disposed at a position facing the back material 14 as a whole. (Second function).

  The wavelength of the electromagnetic wave transmitted or received from the electromagnetic wave transceiver applied in the present embodiment is a millimeter wave (about 4 mm), and this millimeter wave passes depending on the thickness dimension of the decorative member 10 (particularly the surface material 12). The attenuation rate is different. Further, the attenuation rate varies depending on the material (mainly, the front material 12 and the back material 14).

  Therefore, an upper limit value is set for the attenuation rate (dB) of the millimeter wave, and the one that satisfies the upper limit value is selected. In addition, since a suitable plate thickness as the decorative member 10 is about 5 to 8 mm, when this plate thickness is satisfied and, for example, the upper limit value of the attenuation rate is set to 2 dB, the following results are obtained. .

  Candidate 1 or 2 is selected based on the dielectric constant of the material. In the case of polycarbonate resin, the attenuation is low when it is a multiple of 1.2 mm.

(Manufacturing method of the decorative member 10)
First, as shown in FIG. 5A, a reflection sheet 22 is prepared in order to generate the substrate 16. As described above, the reflection sheet 22 is produced by laminating (about 400 or 800 layers) polyethylene resin film layers that do not transmit light in different frequency bands, and is commercially available as a product. ing.

  Next, as shown in FIG. 5B, the reflective sheet 22 is cut into the outer shape of the base material 16 of the decorative member 10 and a printed layer 24 is applied. Here, the reflective sheet 22 is cut into an oval shape, and a black printed layer 24 is applied to two island-like regions (symmetrical shapes). In addition, since the printing layer 24 which is not black is transparent and the surface of the reflective sheet 22 is exposed, it becomes a mirror surface.

  In addition, the printing pattern of the printing layer 24 is based on the design which can be applied, and is not limited to two island-like regions (symmetrical shapes) as described above. For example, an elliptical periphery and a part that represents an initial letter (such as an alphabet) that emphasizes a design object may be a mirror surface, and the other may be a background color (such as black).

  In FIG.5 (C), the adhesive layers 18 and 20 which become colorless and transparent at least at the time of hardening are provided in each of the surface and the back surface of the base material 16 (total reflection sheet 22 and printing layer 24). The adhesive layers 18 and 20 may be attached in advance as film layers, or may be applied and dried.

  In addition, a film of the same system as the material to be injected may be laminated on the front and back surfaces of the laminated film of polyethylene resin so as to replace the adhesive layers 18 and 20.

  The base material 16 formed in this way is set in a surface molding die 26 as shown in FIG.

  At this time, unevenness is formed in the lower mold 26L, and the base material 16 is three-dimensionally bent and deformed according to the unevenness. In the base material 16 that has been bent and deformed, the convex portion has a mirror finish, and the concave portion becomes a black region of the printed layer 24.

  The upper mold 26U is set on the lower mold 26L on which the base material 16 is set. At this time, a space is created between the adhesive layer 18 on the surface side of the base material 16 and the ceiling surface of the upper mold 26U, and a transparent synthetic resin to be the surface material 12 is injected from the injection port 28.

  At this time, the injection port 28 has an elevation angle θ with respect to the horizontal, not the normal horizontal. This is for injecting the synthetic resin toward the ceiling surface of the upper mold 26U. In other words, a device is provided that does not spray the adhesive layer 18 directly.

  As a result, the temperature of the adhesive layer 18 does not become uneven, the temperature rises uniformly, and then falls, so that the adhesion between the base material 16 and the surface material 12 is ensured.

  When the surface material 12 is solidified, next, as shown in FIG.

  At this time, the lower mold 30L has a recessed shape that matches the shape of the surface material 12 (dome shape), and is set with the surface material 12 facing downward.

  The upper mold 30U is set on the lower mold 30L on which the assembly of the base material 16 and the surface material 12 is set. At this time, a space is formed between the adhesive layer 20 on the back surface (here, the upper surface) side of the base material 16 and the ceiling surface of the upper mold 30U, and the black synthetic resin that becomes the back material 14 from the injection port 32 is formed. inject.

  When the backing 16 is solidified, the decorative member 10 is completed as shown in FIG.

  The decorative member 10 is a member that visually (designally) requires a metallic appearance and needs to pass electromagnetic waves.

  Therefore, since the base material 16 is made of a synthetic resin total reflection sheet 22 made of a polycarbonate or the like in order to obtain a metallic tone, and a metallic tone is obtained, a metal that restricts the movement of electrons is not used. Millimeter wave electromagnetic waves can be reliably transmitted.

  Moreover, since the printing layer 24 and the adhesive layers 18 and 20 have a role as a heat blocking layer that suppresses heat transfer to the reflection sheet 22 during molding, the original function (metal tone, mirror surface) of the reflection sheet 22 is achieved. There is no loss.

  Note that the print layer 24 may have an adhesive function depending on the material, and may also be used as the adhesive layer 18.

  The operation of this embodiment will be described below.

  6 to 8 show an embodiment in which the decorative member 10 of the present invention is applied as an ornament 10A of a vehicle 50. FIG.

  As shown in FIGS. 6 to 8, the front face surface, which is the front end portion of the engine hood 52 provided in front of the vehicle 50, is provided with headlights 54 at both ends in the vehicle width direction. A bumper 56 is attached to the lower end portion of the headlight 54 so as to be spanned between the left and right headlights 54 and to wrap around the side surface of the vehicle 50.

  Here, in a rectangular space surrounded by the engine hood 52, the pair of headlights 54, and the bumper 56, a radiator grill 58 is attached as a decorative member. The radiator grill 58 may be attached to the engine hood 52, or may be attached to a vehicle body (not shown) between the pair of headlights 54.

  The radiator grill 58 is composed of a plurality of louvers 58A (see FIG. 7) provided with a predetermined gap in order to send air into a radiator (not shown). In addition, since it is sufficient if there is a gap, not only the louver 58A but also a structure formed in a honeycomb shape may be used.

  The radiator grill 58 is chrome-plated. On the other hand, the ornament 10A attached to the center of the front surface of the radiator grill 58 is all made of synthetic resin.

  The ornament 10 </ b> A is generated using a mark or the like for specifying the manufacturer or model of the vehicle 50 as a motif. This molded product is the decorative member 10 (see FIG. 1). Accordingly, the base material 16 formed of a metallic total reflection sheet can be seen through the surface material 12 on the surface of the ornament 10A facing the front of the vehicle.

  A millimeter wave radar 60 is disposed on the vehicle rear side of the ornament 10A. The millimeter wave radar 60 is a detection terminal that outputs an electromagnetic wave having a predetermined frequency (millimeter wave) in front of the vehicle 50, receives the electromagnetic wave (reflected wave) reflected by an obstacle, and measures the distance. . For example, a principle such as the Sing Arland method applied to a fish finder can be applied.

  The distance information to the obstacle detected by the millimeter wave radar 60 is applied to, for example, early detection of an obstacle, assistance for a visual field, collision prediction, and the like so as to be used as equipment for promoting safety during driving. It has become.

  Such a millimeter-wave radar 60 is arranged on the vehicle rear side of the ornament 10A, so that the ornament 10A also serves as a protector against wind and rain while the vehicle is running. Thereby, the lifetime of the millimeter wave radar 60 can be extended.

  Further, the decorative member 10 (see FIG. 1) described above is applied to the ornament 10A. Therefore, the first function as the ornament 10A, that is, the gloss that looks like a metallic tone is maintained, and the second function, that is, the electromagnetic wave output from the millimeter wave radar 60 and the reflected wave are surely passed. Can be made.

  In the present embodiment, the example in which the decorative member 10 (see FIG. 1) is applied as the ornament 10A attached to the radiator grill 58 of the vehicle 50 has been described. However, in order to allow the electromagnetic wave to pass through and to appear metallic. This part may be used as a member for concealing the part (for example, a millimeter wave radar that detects an obstacle on the rear side or both sides of the vehicle).

  Furthermore, it is a casing of a mechanism that transmits radio waves from the inside or receives radio waves from the outside, not limited to vehicles, and can be applied when a metallic appearance is required.

10 decorative member 12 surface material (synthetic resin)
14 Back material (synthetic resin)
16 Base material 18, 20 Adhesive layer 22 Total reflection sheet 24 Print layer 26 Mold (surface shaping mold)
26L Lower mold 26U Upper mold 28 Inlet 30 Mold (mold for back side shaping)
30L Lower mold 30U Upper mold 32 Inlet 50 Vehicle 10A Ornament 52 Engine hood 54 Headlight 56 Bumper 58 Radiator grill 58A Louver 60 Millimeter wave radar

Claims (6)

By laminating polyethylene resin film layers that do not transmit light in different frequency bands, a base material provided with a printed layer on which at least one surface of a total reflection sheet that totally reflects light is printed is provided. , A decorative member molded by setting a predetermined mold and injecting synthetic resin on the front and back surfaces of the base material,
An ornamental member characterized in that an adhesive layer is provided on the front and back surfaces of the base material, melts when the synthetic resin is injected, and the base material and the synthetic resin are brought into close contact with each other.   The decorative member according to claim 1 or 2, wherein the synthetic resin injection is injection by injection molding, and an injection direction thereof is a mold ceiling surface through a synthetic resin injection space on the adhesive layer. .   The decorative member according to claim 1 or 2, wherein the film layer is made of a polyethylene material, and acrylic printing ink is applied to the printing, and the acrylic printing ink also serves as an adhesive layer.   The film layer is a polyethylene material, and the laminate film functions as an alternative to the adhesive layer by laminating a film of the same system as the material to be injected on the front and back surfaces of the polyethylene resin laminate film. The decorative member according to claim 1 or 2. The decorative member according to any one of claims 1 to 3,
A distance detecting radar that outputs an electromagnetic wave in a predetermined direction and receives a reflected wave of the output electromagnetic wave to measure a distance to a reflection target;
The radar unit, wherein the decorative member is disposed at least on the electromagnetic wave output surface side of the distance detection radar and conceals the distance detection radar. Front and back surfaces of a base material that has been cut into a predetermined shape from a total reflection sheet that totally reflects light by laminating polyethylene resin film layers that do not transmit light in different frequency bands. An adhesive layer is provided on the
The base material with the adhesive layer is set in a surface molding die, and a synthetic resin is injected into the surface side to dissolve the adhesive layer, thereby bringing the base material and the solidified synthetic resin into close contact with each other. As an assembly,
The assembly is set in a back surface molding die, and a synthetic resin is injected into the back surface side, so that the adhesive layer is dissolved and the base material and the synthetic resin are brought into close contact with each other in the curing process of the synthetic resin. The decorative member manufacturing method produced | generated in.

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