JP2022025403A - Radar cover and method for manufacturing radar cover - Google Patents

Abstract

To prevent generation of an indentation produced by pressure in a radiant region in a radar cover in which a radiant colored member is arranged between a transparent member and a support member.SOLUTION: The present invention relates to a radar cover 10 for covering a radar unit R for detecting situations around a vehicle, the radar cover including: a transparent member 11 with a recessed part 11a in the back surface; an inner core 12 contained in the recessed part 11a; a sealing gas layer 14 made of a sealing gas, formed between the inner core 12 and the inner wall surface of the recessed part 11a; and a base member 13 for supporting the transparent member 11 and the inner core 12 from the back side.SELECTED DRAWING: Figure 2

Description

The present invention relates to a radar cover and a method for manufacturing a radar cover.

In recent years, radar units that detect obstacles and the like around the vehicle using radio waves such as millimeter waves have been mounted on the vehicle. Such a radar unit is arranged inside a radiator grill or an emblem provided on the front surface of the vehicle, and transmits / receives radio waves transmitted through the radiator grill or the like. Therefore, in a vehicle equipped with the radar unit as described above, it is necessary to form the radiator grille and the emblem so that the radio waves can be transmitted while suppressing the attenuation of the radio waves.

On the other hand, since the radiator grille and the emblem are arranged on the front surface of the vehicle, they are extremely important parts in the design of the vehicle, and are often given brilliance in order to improve the sense of quality and texture. In the past, in order to impart such brilliance, it was common to perform a plating process, but the plating layer does not transmit radio waves. For this reason, in recent years, a technique for forming a brilliant film capable of transmitting radio waves has been used in order to impart brilliance and allow radio waves to pass through (see Patent Document 1).

Japanese Unexamined Patent Publication No. 2011-46183

However, as in Patent Document 1, when a bright colored member such as an inner core having a gloss is provided as a separate body between the transparent member and the support member, the bright colored member strongly presses against the transparent member or the like. As a result, crimping marks may be generated in the bright region.

The present invention has been made in view of the above-mentioned problems, and it is intended to prevent a crimping mark from being generated in a bright region in a radar cover in which a bright colored member is arranged between a transparent member and a support member. The purpose.

The present invention has the following configuration as a means for solving the above problems.

The first invention is a radar cover for covering a radar unit for detecting the surrounding condition of a vehicle, which is a transparent member having a recess on the back surface, a brilliant colored member housed in the recess, and the brilliant colored member. It has a configuration including a cushion gas layer provided between the member and the inner wall surface of the recess and formed by the enclosed gas, and a support member for supporting the transparent member and the brilliant colored member from the back surface side. ..

The second invention has a configuration in which the enclosed gas is compressed air in the first invention.

In the third invention, in the first or second invention, the glittering colored member is a metal having a base made of resin and a metal having radio wave transmission on the surface of the base on the inner wall surface side of the recess. It has a structure having a glossy layer.

In the fourth aspect of the invention, in any one of the first to third inventions, the support member is formed of a resin and welded to the back surface of the transparent member and the back surface of the brilliant colored member. Has.

A fifth invention is a method for manufacturing a radar cover that covers a radar unit that detects the surrounding condition of a vehicle, that is, a transparent member forming step of forming a transparent member having a recess on the back surface, and a brightly colored recess. The transparent member and the brilliant colored member are supported from the back side while supplying an enclosed gas between the brilliant colored member arranging step of arranging the member and the inner wall surface of the brilliant colored member and the recess. It has a configuration including a support member forming step for forming a support member.

The sixth invention has a configuration in which compressed air is supplied as the enclosed gas in the support member forming step in the fifth invention.

According to the seventh aspect of the invention, in the fifth or sixth invention, the radio wave transmission is provided on the inner wall surface side of the base portion made of resin and the concave portion of the base portion in the brilliant colored member arranging step. It has a configuration in which the brightly colored member having the metallic luster layer having the above is arranged in the recess.

The eighth invention is the back surface of the transparent member in which the bright colored member is arranged in the recess while supplying the enclosed gas in the support member forming step in any of the fifth to seventh inventions. It has a configuration in which the support member is formed on the side by injection molding.

According to the present invention, a cushion gas layer formed by the enclosed gas is provided between the inner wall surface of the recess provided in the transparent member and the brilliant colored member. Therefore, it is possible to prevent the brilliant colored member from being strongly pressed against the inner wall surface of the recess by the cushion gas layer. Therefore, according to the present invention, in the radar cover in which the bright colored member is arranged between the transparent member and the support member, it is possible to prevent the crimping marks from being generated in the bright region.

It is a front view of the radiator grill provided with the radar cover in one Embodiment of this invention. It is an enlarged front view of the radar cover in one Embodiment of this invention. It is sectional drawing of the radar cover in one Embodiment of this invention. It is a schematic diagram for demonstrating the manufacturing method of the radar cover in one Embodiment of this invention.

Hereinafter, an embodiment of the radar cover and the method for manufacturing the radar cover according to the present invention will be described with reference to the drawings.

FIG. 1A is a front view of the radiator grill 1 provided with the radar cover 10 of the present embodiment. Further, FIG. 1B is an enlarged front view of the radar cover 10 of the present embodiment. Further, FIG. 2 is a cross-sectional view of the radar cover 10 of the present embodiment.

The radiator grill 1 is provided on the front surface of the vehicle so as to close the opening leading to the engine room of the vehicle, ensuring ventilation to the engine room and preventing foreign matter from entering the engine room. In the center of the radiator grill 1, a radar cover 10 is provided so as to face the radar unit R (see FIG. 2) arranged in the engine room. The radar unit R has, for example, a transmitting unit that transmits millimeter waves, a receiving unit that receives reflected waves, an arithmetic unit that performs arithmetic processing, and the like. The radar unit R transmits and receives radio waves transmitted through the radar cover 10, and detects the surrounding conditions of the vehicle based on the received radio waves. For example, the radar unit R calculates and outputs the distance to the obstacle, the relative speed of the obstacle, and the like.

The radar cover 10 is arranged so as to cover the radar unit R when viewed from the front side of the vehicle. That is, the radar cover 10 is arranged with its back surface facing the radar unit R. As shown in FIG. 1B, the radar cover 10 improves the visibility of the bright region 10A representing figures, characters, etc. showing the emblem of the vehicle manufacturer and the bright region 10A when viewed from the front side of the vehicle. It is a component having a black region 10B to be caused. As shown in FIG. 2A, such a radar cover 10 includes a transparent member 11, an inner core 12 (brilliant colored member), a base member 13 (support member), and an enclosed gas layer 14 (cushion gas layer). ) And.

The transparent member 11 is a portion formed of a substantially rectangular transparent material (including colored transparent material) arranged on the outermost side of the vehicle. In order to improve the visibility of the inner core 12 from the outside of the vehicle, the transparent member 11 has a smooth surface on the front side. Further, a recess 11a in which the inner core 12 is arranged is formed on the back surface of the transparent member 11.

The recess 11a is a portion where the inner core 12 is fitted, and the accommodated inner core 12 is three-dimensionally visible from the front side of the vehicle. The recess 11a is provided along the shape of a figure such as an emblem of a vehicle manufacturer or a character. By accommodating the inner core 12 in such a recess 11a, the above-mentioned bright region 10A is formed.

Such a transparent member 11 is formed of, for example, a transparent synthetic resin such as colorless PC (polycarbonate) or PMMA (polymethylmethacrylate resin), and has a thickness of about 1.5 mm to 10 mm. Further, the front surface of the transparent member 11 is subjected to a hard coat treatment for preventing scratches or a clear coat treatment of urethane-based paint, if necessary. If it is a transparent synthetic resin having scratch resistance, these scratch prevention treatments are unnecessary.

The inner core 12 includes a base 12a and a glittering film 12b. The base portion 12a is a strength member that serves as a skeleton of the inner core 12, and supports the glittering film 12b. The base portion 12a is molded by injection molding or the like, and is formed of, for example, a synthetic resin such as ABS, PC or PET. The base portion 12a has a convex shape in which at least a part of the recess 11a of the transparent member 11 is embedded.

The brilliant film 12b is a glossy layer formed of a thin film having a metallic luster (metallic color) and radio wave transmission, which is formed so as to cover the surface of the base portion 12a. The brilliant film 12b is a metal thin film made of indium (In) formed by, for example, vacuum deposition or sputtering, and is a discontinuous film having a large number of fine gaps. Further, the brilliant film 12b may be a thin film formed of an alloy containing a semiconductor and a metal. Specifically, the glitter film 12b can be formed by an alloy of a semiconductor such as silicon (Si) or germanium (Ge) and a metal such as aluminum (Al) or chromium (Cr). The glitter film 12b formed of such an alloy contains a semiconductor having less free electrons than a metal, and has a property of transmitting electromagnetic waves.

Further, a base coat layer (not shown) is provided between the glitter film 12b and the base portion 12a, and a top coat layer (not shown) is provided on the surface of the glitter film 12b. The base coat layer is formed between the base portion 12a and the glittering film 12b, and is for improving the adhesion between the base portion 12a and the glittering film 12b. This base coat layer is formed, for example, by clear coating using a transparent (including colored transparent) synthetic resin. When a brilliant film having high adhesion is used, the base coat layer can be omitted.

The top coat layer is formed on the brilliant film 12b so as to cover the brilliant film 12b, and is for protecting the brilliant film 12b. Like the base coat layer, this top coat layer is also formed by clear coating using a transparent (including colored transparent) synthetic resin.

The base coat layer and the top coat layer may be a transparent ceramic coat layer made of silicon oxide (SiOx). In this case, it has higher heat resistance and higher radio wave transparency as compared with a base coat layer or a top coat layer made of a resin formed by clear coating or the like.

The inner core 12 is fixed by welding the base portion 12a to the surface of the base member 13. An enclosed gas layer 14 is provided between the inner wall surface of the recess 11a of the transparent member 11 and the inner core 12. That is, the inner core 12 is fixed to the surface of the base member 13 by welding, but is not fixed to the inner wall surface of the recess 11a of the transparent member 11.

The base member 13 is a portion fixed to the back surface side of the transparent member 11, and is formed of a black resin material. The base member 13 is fixed to the transparent member 11 and functions as a support member that supports the inner core 12 from the side opposite to the transparent member 11. Further, the base member 13 has an engaging portion 13a protruding toward the engine room side. The tip of the engaging portion 13a is formed in a claw shape, and the tip is locked to, for example, a radiator grill main body. The base member 13 thus fixed to the back surface of the transparent member 11 is visible from the outside of the transparent member 11 and forms the black region 10B described above. The base member 13 makes a region other than the bright region 10A visible in black, and relatively improves the visibility of the bright region 10A.

Such a base member 13 includes ABS (acrylonitrile / butadiene / styrene copolymer synthetic resin), AES (acrylonitrile / ethylene / styrene copolymer synthetic resin), ASA (acrylonitrile / styrene / acrylate), PBT (polybutylene terephthalate), and the like. It is made of colored PC, synthetic resin such as PET (polybutylene terephthalate), or a composite resin thereof, and has a thickness of about 0.5 mm to 10 mm.

The filled gas layer 14 is a layer formed by the filled gas sealed between the inner wall surface of the recess 11a of the transparent member 11 and the inner core 12. The enclosed gas layer 14 is formed of, for example, air or nitrogen gas, and prevents the inner core 12 from coming into contact with the recess 11a of the transparent member 11. As shown in FIG. 2, the space in which the filled gas layer 14 is provided is a closed space. Therefore, when the inner core 12 or the base member 13 to which the inner core 12 is fixed tries to be deformed so as to crush the enclosed gas layer 14 due to thermal deformation or the like, the internal pressure of the enclosed gas layer 14 increases. Due to such an increase in the internal pressure of the filled gas layer 14, it is possible to prevent the inner core 12 from approaching the inner wall surface of the recess 11a of the transparent member 11. That is, it is possible to prevent the inner core 12 from approaching the inner wall surface of the recess 11a of the transparent member 11 due to the restoring force (elastic force) generated when the filled gas is compressed. In particular, in the manufacturing process of the radar cover 10 described later, the enclosed gas layer 14 can prevent the inner core 12 from coming into contact with the inner wall surface of the recess 11a of the transparent member 11.

For example, the pressure inside the filled gas layer 14 can be higher than the atmospheric pressure. Since the pressure inside the filled gas layer 14 becomes higher than the atmospheric pressure, the restoring force generated when the filled gas is compressed can be further enhanced. Therefore, the enclosed gas layer 14 can more reliably prevent the inner core 12 from coming into contact with the inner wall surface of the recess 11a of the transparent member 11.

As shown in FIG. 2, such an enclosed gas layer 14 is provided so as to cover the entire area of the inner core 12 when viewed from the transparent member 11 side. This makes it possible to prevent the entire area of the inner core 12 from coming into contact with the inner wall surface of the recess 11a of the transparent member 11.

Subsequently, a method of manufacturing the radar cover 10 of the present embodiment will be described with reference to FIGS. 3 and 4. FIG. 3 is a schematic diagram for explaining a method of manufacturing the radar cover 10 of the present embodiment. First, as shown in FIG. 3A, the transparent member 11 is formed. For example, the transparent member 11 is formed by injection molding. Since the transparent member 11 having the recess 11a can be formed by this injection molding, it is not necessary to form the recess 11a in a subsequent step. If necessary, the surface side (the surface facing the outside of the vehicle) or the entire surface of the transparent member 11 may be subjected to a hard coat treatment for improving durability and the like. Such a step shown in FIG. 3A is a transparent member forming step.

Subsequently, as shown in FIG. 3 (b), the inner core 12 is formed. For example, the base is formed by injection molding. In addition, a base coat layer is formed by clear coating the base and then drying. In addition, a glitter film is formed on the base coat layer by sputtering or vacuum deposition. Further, a top coat layer is formed by applying a clear coating on the surface of the brilliant film and then drying it. It is not necessary to wait for the formation of the transparent member 11 shown in FIG. 3A before forming the inner core 12. By forming the inner core 12 in parallel with the process of forming the transparent member 11 shown in FIG. 3A, the manufacturing time of the radar cover 10 can be shortened.

Subsequently, as shown in FIG. 3C, the inner core 12 is arranged in the recess 11a of the transparent member 11. Here, for example, the inner core 12 is arranged in a state of being in contact with the bottom of the recess 11a. Such a step shown in FIG. 3C is an inner core arranging step (a brilliant colored member arranging step) in which the inner core 12 is arranged in the recess 11a.

Next, as shown in FIG. 3D, the base member 13 is formed. Here, the transparent member 11 in which the inner core 12 is installed in the recess 11a is placed inside the mold for injection molding, and insert molding (injection molding) is performed in which the molten resin is injected onto the back surface side of the transparent member 11. This forms the base member 13.

FIG. 4 is an enlarged schematic diagram for explaining the process of forming the base member 13 in more detail. As shown in FIG. 4A, after arranging the transparent member 11 in which the inner core 12 is arranged in the recess 11a inside the mold, compressed air G (filled gas) is supplied to the cavity of the mold. Compressed air G is sprayed onto the back surface of the transparent member 11. When such compressed air G is supplied to the cavity of the mold, for example, an air venting flow path provided for venting the air in the cavity to the outside can be used for supplying the compressed air G. As described above, if the mold is already provided with a flow path for bleeding air, it is not necessary to form a new flow path by diverting the flow path for bleeding air as a supply flow path for compressed air G.

Subsequently, as shown in FIG. 4B, the molten resin 20 is supplied into the cavity while continuing to inject the compressed air G onto the back surface of the transparent member 11. By supplying such molten resin 20 into the cavity, the escape area of the compressed air G is reduced, and the compressed air G is pushed between the inner core 12 and the inner wall surface of the recess 11a of the transparent member 11. In this way, the compressed air G pushed in between the inner core 12 and the inner wall surface of the recess 11a of the transparent member 11 is sealed to form the enclosed gas layer 14.

When the molten resin 20 is cooled, it becomes a base member 13. At this time, the base member 13 is welded to the transparent member 11 by the heat during insert molding, and is arranged so as to cover the inner core 12. The back surface of the inner core 12 is also welded to the base member 13. As a result, the inner core 12 is supported by the base member 13.

When the molten resin 20 is cooled, the transparent member 11 fixed to the molten resin 20 is attracted to the base member 13, but the enclosed gas layer 14 prevents the transparent member 11 from coming into contact with the surface of the inner core 12. To.

Such steps shown in FIGS. 3 (d), 4 (a) and 4 (b) are transparent while supplying an enclosed gas (compressed air G) between the inner core 12 and the inner wall surface of the recess 11a. This is a base member forming step (support member forming step) for forming a base member 13 that supports the member 11 and the inner core 12 from the back surface side.

The radar cover 10 of the present embodiment is manufactured by the above steps. Such a radar cover 10 of the present embodiment is arranged so as to cover the radar unit R that detects the surrounding condition of the vehicle. Further, the radar cover 10 of the present embodiment is provided and enclosed between the transparent member 11 provided with the recess 11a on the back surface, the inner core 12 housed in the recess 11a, and the inner wall surface of the inner core 12 and the recess 11a. It includes an enclosed gas layer 14 formed of gas, and a base member 13 that supports the transparent member 11 and the inner core 12 from the back surface side.

According to the radar cover 10 of the present embodiment as described above, the filled gas layer 14 formed by the filled gas is provided between the inner wall surface of the recess 11a provided in the transparent member 11 and the inner core 12. Therefore, it is possible to prevent the inner core 12 from being strongly pressed against the inner wall surface of the recess 11a by the filled gas layer 14. Therefore, according to the radar cover 10 of the present embodiment, it is possible to prevent a crimping mark from being generated in the bright region 10A in the radar cover 10 in which the inner core 12 is arranged between the transparent member 11 and the base member 13. Will be.

Further, the method of manufacturing the radar cover 10 of the present embodiment is a method of manufacturing the radar cover 10 that covers the radar unit R that detects the surrounding condition of the vehicle. Such a method for manufacturing the radar cover 10 of the present embodiment includes a transparent member forming step of forming a transparent member 11 having a recess 11a on the back surface, an inner core arranging step of arranging an inner core 12 in the recess 11a, and an inner core 12. It has a base member forming step of forming a base member 13 that supports the transparent member 11 and the inner core 12 from the back surface side while supplying the filled gas (compressed air G) between the recess 11a and the inner wall surface of the recess 11a. There is. Therefore, the filled gas layer 14 formed between the inner core 12 and the inner wall surface of the recess 11a by the filled gas (compressed air G) suppresses the inner core 12 from being strongly pressed against the inner wall surface of the recess 11a. be able to. Therefore, according to the radar cover 10 of the present embodiment, it is possible to prevent a crimping mark from being generated in the bright region 10A in the radar cover 10 in which the inner core 12 is arranged between the transparent member 11 and the base member 13. Will be.

Further, in the method of manufacturing the radar cover 10 and the radar cover 10 of the present embodiment, compressed air G is used as the enclosed gas. Therefore, it is possible to form the enclosed gas layer 14 by using an inexpensive gas. However, it is also possible to use an inert gas or the like as the filled gas.

Further, in the method of manufacturing the radar cover 10 and the radar cover 10 of the present embodiment, the inner core 12 is a metal having a radio wave transmission property provided on the inner wall surface side of the base portion 12a made of resin and the recess 11a of the base portion 12a. It has a brilliant film 12b made of. According to the radar cover 10 of the present embodiment as described above, since the bright region 10A is formed by the metal, it is possible to further improve the appearance impression of the bright region 10A.

Further, in the method of manufacturing the radar cover 10 and the radar cover 10 of the present embodiment, the base member 13 is formed of resin and welded to the back surface of the transparent member 11 and the back surface of the inner core 12. Therefore, the transparent member 11 and the inner core 12 can be firmly fixed to the base member 13 as compared with the case where the transparent member 11 and the inner core 12 are adhered to the base member 13 with an adhesive or the like. .. Therefore, it is possible to further improve the airtightness of the enclosed gas layer 14.

Although the preferred embodiment of the present invention has been described above with reference to the accompanying drawings, it goes without saying that the present invention is not limited to the above embodiment. The various shapes and combinations of the constituent members shown in the above-described embodiment are examples, and can be variously changed based on design requirements and the like without departing from the spirit of the present invention.

For example, in the above embodiment, the configuration in which the bright film 12b is a metallic luster layer made of metal has been described. However, the glittering film 12b may be any layer as long as it has a gloss, and is not limited to a metal (indium) or a semiconductor alloy. The glitter film 12b can also be a thin film coated with a glossy paint.

Further, in the above embodiment, an example in which the inner core 12 provided with the base portion 12a and the brilliant film 12b is used as the brilliant colored member has been described. However, the present invention is not limited to this, and any member having a brilliant surface can be used as a brilliant colored member.

Further, in the above embodiment, the configuration in which the block-shaped inner core 12 is used as the brilliant colored member has been described. However, in the present invention, the brilliant colored member does not necessarily have to be a block-shaped member. For example, it is also possible to use a film-like member having a brilliant property as a brilliant colored member.

1 ... Radiator grill, 10 ... Radar cover, 10A ... Bright area, 10B ... Black area, 11 ... Transparent member, 11a ... Recess, 12 ... Inner core (brilliant colored member), 12a ... Base , 12b ... Bright film, 13 ... Base member, 13a ... Engagement part, 14 ... Filled gas layer, 20 ... Molten resin, G ... Compressed air (filled gas), R ... Radar unit

Claims (8)

A radar cover that covers the radar unit that detects the surrounding conditions of the vehicle.
A transparent member with a recess on the back and
The bright colored member housed in the recess and
A cushion gas layer provided between the brilliant colored member and the inner wall surface of the recess and formed by the enclosed gas,
A radar cover including a support member that supports the transparent member and the brilliant colored member from the back surface side. The radar cover according to claim 1, wherein the enclosed gas is compressed air. The brilliant colored member is
The base made of resin and
The radar cover according to claim 1 or 2, wherein the radar cover has a metallic luster layer having radio wave transmission provided on the surface of the base portion on the inner wall surface side of the recess. The radar cover according to any one of claims 1 to 3, wherein the support member is formed of a resin and welded to the back surface of the transparent member and the back surface of the brilliant colored member. It is a method of manufacturing a radar cover that covers the radar unit that detects the surrounding conditions of the vehicle.
A transparent member forming process for forming a transparent member having a recess on the back surface,
A step of arranging a brilliant colored member in the recess and a step of arranging the brilliant colored member,
It has a support member forming step of forming a support member that supports the transparent member and the bright colored member from the back surface side while supplying an enclosed gas between the bright colored member and the inner wall surface of the recess. A method of manufacturing a radar cover, which is characterized by the fact that. The method for manufacturing a radar cover according to claim 5, wherein compressed air is supplied as the enclosed gas in the support member forming step. In the brilliant colored member placement process,
A claim comprising arranging the brilliant colored member having a base made of a resin and a metallic luster layer having radio wave transmission provided on the surface of the recess on the inner wall surface side of the base in the recess. 5. The method for manufacturing a radar cover according to 5 or 6. In the support member forming step
The invention according to any one of claims 5 to 7, wherein the support member is formed by injection molding on the back surface side of the transparent member arranged in the recess while supplying the enclosed gas. The method of manufacturing the radar cover described.

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