JP6783904B2 - Radar cover and radar cover manufacturing method - Google Patents

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. Generally, the radar unit is installed so as to be covered with a radar cover decorated with an emblem or the like. Such a radar unit transmits and receives radio waves transmitted through the radar cover. Therefore, the radar cover naturally needs to be formed so as to be able to transmit radio waves as disclosed in Patent Document 1, for example.

JP-A-2016-141355

By the way, the radar cover as described above generally has a transparent member arranged toward the outside of the vehicle and a support member for supporting the transparent member from the back side, and the transparent member and the support member are made of resin. It has a structure that is integrated by two-color molding. Therefore, when a colored layer is formed between the transparent member and the support member, the colored layer can be visually recognized from the outside through the transparent member, and an emblem or a pattern can be formed by the colored layer. When a colored layer is formed between the transparent member and the support member, it is conceivable to apply ink to the back surface of the transparent member by printing or the like to form the colored layer.

On the other hand, in order to make the emblem or pattern three-dimensionally visible, it is common practice to form a recess on the back surface of the transparent member. However, the boundary portion between the colored layer forming region on which the colored layer is formed and the inner wall surface of the recess is a curved surface in which the colored layer forming region and the inner wall surface of the recess are connected without bending. Since the transparent member is formed by injection molding, it is generally the case that the surface of the convex portion for forming the concave portion in the mold and the plane forming the colored layer forming region are bent and connected. Due to the difficulty in manufacturing. In the patent documents and the like, the inner wall surface of the recess formed on the back surface of the transparent member is shown to be bent and connected to the plane around it, but this is only schematically shown. In an actual product, the inner wall surface of the recess and the plane around it are connected by a curved surface having a radius of curvature of about 0.5 mm.

By the way, when the boundary portion between the colored layer forming region where the colored layer is formed and the inner wall surface of the recess is a curved surface, for example, the ink when forming the colored layer partially moves along the curved surface before drying. As a result, the edges of the colored layer may unintentionally meander slightly.

Since the radar cover is generally attached to a conspicuous place such as the front surface of the vehicle and forms a deep impression of the appearance of the vehicle, it is preferable to eliminate even a slight meandering at the end of the colored layer. In recent years, due to the design of vehicles, large radar covers that greatly exceed the transmission range of radar have been manufactured, and various patterns and the like have been applied to the radar covers. For this reason, it is desired to propose a technique for reliably preventing unintended meandering at the end of the colored layer in the radar cover.

The present invention has been made in view of the above-mentioned problems, and in a radar cover in which a colored layer is formed between a transparent member having a recess on the back surface and a support member, an end portion of the colored layer is unintentionally formed. The purpose is to prevent meandering.

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

The first invention is a radar cover arranged on a radio wave traveling path of a radar unit that detects the surrounding condition of a vehicle, and is joined to a transparent member and the back surface of the transparent member and supports the transparent member. The transparent member is provided with a colored layer formed on the surface of the transparent member on the support member side and arranged between the transparent member and the support member. A configuration is adopted in which the inner wall surface is connected to the colored layer forming region by bending with respect to the formed colored layer forming region.

In the second invention, in the first invention, the transparent member has a coating recess as the recess, in which a paint having a color different from that of the colored layer is applied to the inner wall surface.

The third invention adopts the configuration in which the paint covers the surface of the colored layer on the support member side in the second invention.

The fourth invention adopts the configuration in any one of the first to third inventions, wherein the transparent member has an inner core accommodating recess in which an inner core having a brilliant discontinuous film is accommodated as the recess. ..

A fifth invention is a method for manufacturing a radar cover arranged on a radio wave path of a radar unit that detects the surrounding condition of a vehicle, in which the radar cover is joined to a transparent member and the back surface of the transparent member. A support member for supporting the transparent member and a colored layer formed on the surface of the transparent member on the support member side and arranged between the transparent member and the support member are provided. The transparent member forming step of forming the transparent member having a recess to which the inner wall surface is connected by bending with respect to the colored layer forming region where the colored layer is formed, and the colored layer forming region of the transparent member. A support member forming step of forming the support member by covering the surface of the transparent member on the colored layer forming region side is adopted.

In the sixth invention, in the fifth invention, the configuration in which the colored layer is formed by the printing method in the colored layer forming step is adopted.

According to the seventh invention, in the fifth or sixth invention, a paint having a color different from that of the colored layer is applied to at least a part of the inner wall surface of the recess before the support member forming step. Adopt a configuration in which the process is performed.

In the eighth invention, in the seventh invention, in the coating step, the configuration in which the coating material is applied over the colored layer is adopted.

A ninth aspect of the present invention is the inner core installation step of accommodating an inner core having a brilliant discontinuous film in at least a part of the recess before the support member forming step in any of the fifth to eighth inventions. Adopt the configuration of doing.

According to the present invention, the colored layer forming region and the inner wall surface of the recess are bent and connected on the surface of the transparent member on the support member side. Therefore, it is possible to prevent the end portion of the colored layer formed in the colored layer forming region from unintentionally meandering.

It is a front view which shows typically the radar cover in one Embodiment of this invention. (A) is a sectional view taken along the line AA of FIG. 1, and FIG. 1B is a sectional view taken along the line BB of FIG. (A) is an enlarged view of the coating recess shown in FIG. 2 (b), and (b) is an enlarged view of the boundary portion between the coating recess and the print layer forming region in (a). It is a schematic diagram for demonstrating the manufacturing method 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. It is a schematic diagram for demonstrating the manufacturing method 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. 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. In the drawings below, the scale of each member is appropriately changed in order to make each member recognizable.

FIG. 1 is a front view schematically showing the radar cover 1 of the present embodiment. 2 (a) is a cross-sectional view taken along the line AA of FIG. 2 (b) is a cross-sectional view taken along the line BB of FIG. As shown in FIG. 1, the radar cover 1 of the present embodiment has an emblem E arranged at the center and a mesh-like outer design portion D provided around the emblem E. In FIG. 1, a part of the emblem E and the outer design portion D is shown in white, but the region shown in white is assumed to be silver in the present embodiment. Further, the region indicated by the dot pattern of the emblem E and the outer design portion D is black in the present embodiment.

As shown in FIGS. 2A and 2B, the radar cover 1 of the present embodiment is arranged so as to cover the radar unit X for detecting the surrounding condition of the vehicle from the front side of the vehicle. It has transparency to the radio waves used in the unit X. Such a radar cover 1 of the present embodiment is arranged on the radio wave traveling path of the radar unit X (the region where the radio wave emitted from the radar unit X is propagated), and is arranged in FIGS. 2A and 2A. As shown in (b), a transparent member 2, a printing layer 3 (colored layer), a coating layer 4, an inner core 5, and a support member 6 are provided.

The transparent member 2 is made of a transparent resin material and is the member most arranged on the outer side of the vehicle among the constituent members of the radar cover 1. The front surface of the transparent member 2 is a smooth surface in order to enhance the visibility of the emblem E and the outer design portion D from the outside of the vehicle. Further, a recess 2a is formed on the back surface of the transparent member 2 (the surface on the support member 6 side). In the radar cover 1 of the present embodiment, the transparent member 2 has an inner core accommodating recess 2b in which the inner core 5 is accommodated and a coating concave portion 2c in which the paint layer 4 is formed by applying paint to the inner wall surface as the concave portion 2a. It has.

The inner core accommodating recess 2b has a circular shape when viewed from the front, avoiding the letter "F", and is formed in the central portion of the radar cover 1 on which the emblem E is arranged. Such an inner core accommodating recess 2b accommodates the inner core 5 in a state where the inner core 5 is in contact with the inner wall surface.

Further, the coating recess 2c has a frame-shaped portion 2d provided in a frame shape on the outer edge portion of the radar cover 1 when viewed from the front, and a net-like portion 2e provided in a mesh shape inside the frame-shaped portion 2d. There is. A paint layer 4 is provided in such a coating recess 2c so as to cover the inner wall surface. Further, a part of the support member 6 is in a state of being inserted into the coating recess 2c, and the paint layer 4 is covered from the back surface side by the support member 6.

Further, in the present embodiment, the region where the recess 2a on the surface (back surface) of the transparent member 2 on the support member 6 side is not provided is the print layer forming region R (colored layer forming region) on which the print layer 3 is formed. Has been done. The print layer forming region R has a flat surface, and is covered by the print layer 3 from the back surface side of the transparent member 2.

FIG. 3A is an enlarged view of the coating recess 2c shown in FIG. 2B. Further, FIG. 3B is an enlarged view of a further enlarged view of the boundary portion between the coating recess 2c and the print layer forming region R in FIG. 3A. As shown in these figures, in the radar cover 1 of the present embodiment, the inner wall surface of the coating recess 2c is bent and connected to the print layer forming region R at an angle of approximately 90 °. That is, the boundary portion between the inner wall surface of the coating recess 2c and the print layer forming region R is a so-called pin angle. The angle formed by the inner wall surface of the coating recess 2c and the print layer forming region R is preferably 90 °, but may be about 93 ° in consideration of the draft during injection molding.

Further, in the radar cover 1 of the present embodiment, the inner wall surface of the inner core accommodating recess 2b is also bent and connected to the print layer forming region R at an angle of approximately 90 °, similarly to the inner wall surface of the coating recess 2c. ing. That is, the boundary portion between the inner wall surface of the inner core accommodating recess 2b and the print layer forming region R is a so-called pin angle.

Such a transparent member 2 is formed of, for example, a transparent synthetic resin such as colorless PC (polycarbonate) or PMMA (polymethyl methacrylate resin), and has a thickness of about 1.5 mm to 10 mm. Further, the front surface of the transparent member 2 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 print layer 3 is a thin film layer printed on the print layer forming region R of the transparent member 2, and is black as described above in the present embodiment. The print layer 3 is formed by transferring black ink to the print layer forming region R and drying the ink. The print layer 3 can be formed by arranging a black resin ink capable of transmitting radio waves used in the radar unit X on the print layer forming region R by, for example, a silk printing method, and naturally drying the ink. .. Such a print layer 3 is visible from the outside through the transparent member 2, and forms a region shown by a dot pattern shown in FIG.

The paint layer 4 is a thin film layer formed by drying a silver-colored paint capable of transmitting radio waves used in the radar unit X, and is silver-colored as described above in the present embodiment. As shown in FIGS. 2 (a) and 2 (b), the paint layer 4 is provided on the entire back surface of the transparent member 2 on which the print layer 3 is formed, except for the region where the emblem E is formed. ing. That is, the paint layer 4 covers the surface of the print layer 3 on the support member 6 side, except for the region where the emblem E is formed. The paint layer 4 can be formed by, for example, applying a paint containing a pearl pigment and allowing it to air dry. Such a paint layer 4 is visible from the outside through the transparent member 2 in the paint recess 2c, and forms a white region of the outer design portion D shown in FIG.

The inner core 5 has a base made of a resin capable of transmitting radio waves used in the radar unit X, and a brilliant film formed so as to cover the surface of the base. As the brilliant film, for example, an indium film formed as a discontinuous film in which a large number of gaps through which radio waves can be transmitted can be used can be used. Such an indium film can be formed by, for example, a vacuum deposition method or a sputtering method. The inner core 5 may have a transparent top coat layer that covers the surface of the glitter film and an undercoat layer that covers the back surface of the glitter film. Such an inner core 5 is fitted and arranged in the inner core accommodating recess 2b of the transparent member 2 so that the glittering film faces the inner wall surface of the inner core accommodating recess 2b. Such an inner core 5 is visible from the outside through the transparent member 2, and forms a region shown in white of the emblem E shown in FIG.

The support member 6 is a portion joined to the back surface of the transparent member 2 to support the transparent member 2, and is formed of a black resin material. The support member 6 has an engaging portion 6a that projects toward the engine room side. The tip of the engaging portion 6a is formed in a claw shape, and the tip is locked to, for example, a radiator grill body. Such support members 6 include 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 (polyethylene terephthalate), or a composite resin thereof, and has a thickness of about 1.0 mm to 10 mm.

Subsequently, the manufacturing method of the radar cover 1 of the present embodiment will be described with reference to FIGS. 4 to 8.

First, as shown in FIG. 4, the transparent member 2 is formed. Note that FIG. 4A is a cross-sectional view taken at the same position as FIG. 2A, and FIG. 4B is a cross-sectional view taken at the same position as FIG. 2B. Here, the transparent member 2 is formed by injection molding with a mold 10. The mold 10 has a cavity mold 11 on the fixed side and a core mold 12 on the moving side. Further, in the present embodiment, the core mold 12 has a base 12a for forming the print layer forming region R and a nesting 12b for forming the recess 2a. The nesting 12b is separated from the base 12a of the core mold 12, and projects from the surface of the base 12a toward the cavity mold 11 in a state of being fixed to the base 12a. By providing the nesting 12b in the core mold 12 in this way, the surface of the base 12a and the surface of the nesting 12b can be bent and connected, and the print layer forming region R and the inner wall surface of the recess 2a are bent. The transparent member 2 connected to each other can be formed. Such a step shown in FIG. 4 is a step of forming a transparent member 2 having a recess 2a in which an inner wall surface is formed by bending with respect to the print layer forming region R, and corresponds to the transparent member forming step of the present invention. To do.

Subsequently, as shown in FIG. 5, the print layer 3 is formed. 5A is a cross-sectional view taken at the same position as FIG. 2A, and FIG. 5B is a cross-sectional view taken at the same position as FIG. 2B. Here, the printing layer 3 is formed by transferring the ink to the printing layer forming region R, which is the region excluding the recess 2a of the transparent member 2, by a printing method such as a silk printing method, and drying the ink. .. At this time, in the radar cover 1 of the present embodiment, the print layer forming region R and the inner wall surface of the recess 2a are bent and connected. Therefore, the ink transferred to the print layer forming region R moves to the inner wall surface of the recess 2a as compared with the case where the print layer forming region R and the inner wall surface of the recess 2a are connected by a smooth curved surface. hard. According to the method of manufacturing the radar cover 1 of the present embodiment as described above, it is possible to prevent the end portion of the print layer 3 from unintentionally meandering. Such a step shown in FIG. 5 is a step of forming the print layer 3 in the print layer forming region R of the transparent member 2, and corresponds to the colored layer forming step of the present invention.

Subsequently, as shown in FIG. 6, the paint layer 4 is formed. 6 (a) is a cross-sectional view at the same position as FIG. 2 (a), and FIG. 6 (b) is a cross-sectional view at the same position as FIG. 2 (b). Here, in a state where the region M in which the emblem E shown in FIG. 6A is formed is masked, for example, a silver mica paint is spray-coated on the back surface side of the transparent member 2 in which the print layer 3 is formed. , The paint layer 4 is formed by drying the mica paint. The paint layer 4 formed in this way covers the print layer 3 except for the region where the emblem E is formed, and forms the paint layer 4 directly attached to the inner wall surface of all the paint recesses 2c. Such a step shown in FIG. 6 is a step of applying a paint having a color different from that of the printing layer 3 to the inner wall surface of the coating recess 2c which is a part of the recess 2a before forming the support member 6. , Corresponds to the coating process of the present invention.

Subsequently, as shown in FIG. 7, the inner core 5 is accommodated in the inner core accommodating recess 2b. Note that FIG. 7 is a cross-sectional view taken at the same position as FIG. 2 (a). Here, the inner core 5 formed in parallel with the formation of the transparent member 2, the print layer 3, or the paint layer 4 described above is accommodated in the inner core accommodating recess 2b. The inner core 5 is formed by forming a brilliant discontinuous metal film such as an indium layer on the base portion previously formed by injection molding by a vacuum vapor deposition method, a sputtering method, or the like. A top coat layer and an undercoat layer are formed on the inner core 5 as needed. Such an inner core 5 is accommodated in the inner core accommodating recess 2b with a brilliant discontinuous metal film directed toward the inner wall surface side of the inner core accommodating recess 2b. Such a step shown in FIG. 7 is a step of accommodating the inner core 5 having a brilliant discontinuous film in at least a part of the recess 2a, and corresponds to the inner core installation step of the present invention.

Subsequently, as shown in FIG. 8, the support member 6 is formed. 8 (a) is a cross-sectional view at the same position as FIG. 2 (a), and FIG. 8 (b) is a cross-sectional view at the same position as FIG. 2 (b). Here, the transparent member 2 in which the inner core 5 is installed in the inner core accommodating recess 2b is placed inside the mold for injection molding, and insert molding is performed by injecting the molten resin onto the back side of the transparent member 2. , The support member 6 is formed. Such a support member 6 is welded to the transparent member 2 by the heat at the time of insert molding, and is arranged so as to cover the inner core 5. As a result, the inner core 5 is fixed to the transparent member 2. Such a step shown in FIG. 8 is a step of covering the surface of the transparent member 2 on the R side of the print layer forming region R side to form the support member 6, and corresponds to the support member forming step of the present invention.

According to the method of manufacturing the radar cover 1 and the radar cover 1 of the present embodiment as described above, the print layer forming region R and the inner wall surface of the recess 2a are bent on the surface of the transparent member 2 on the support member 6 side. It is connected. Therefore, it is possible to prevent the end portion of the print layer 3 formed in the print layer formation region R from unintentionally meandering. Therefore, the print layer 3 in the emblem E and the outer design portion D can have a shape intended to be cut off, and the reproducibility of the actual design with respect to the design design in the radar cover 1 can be improved.

Further, as shown by the virtual line L in FIG. 3B, when the boundary portion between the print layer forming region R and the inner wall surface of the recess 2a is a curved surface as in the conventional case, the area of the curved surface is accurate. It is difficult to pattern the print layer 3 and the like. Therefore, when the boundary portion between the print layer forming region R and the inner wall surface of the recess 2a is a curved surface as in the conventional case, the curved surface is used as the forming region of the print layer 3 and the paint layer 4 in design. And the curved surface cannot be considered as a design surface. On the other hand, according to the method of manufacturing the radar cover 1 and the radar cover 1 of the present embodiment, since the curved surface does not exist, the entire area between the inner wall surface of the recess 2a and the print layer forming region R is used as the design surface. be able to. That is, according to the method of manufacturing the radar cover 1 and the radar cover 1 of the present embodiment, the design surface can be widely secured, and for example, the three-dimensional appearance of the emblem E and the outer design portion D can be improved.

Further, in the radar cover 1 of the present embodiment, the transparent member 2 has a coating recess 2c as a recess 2a in which a paint having a color different from that of the printing layer 3 is applied to the inner wall surface. Therefore, it is possible to prevent the boundary line between the print layer 3 and the paint layer 4 from unintentionally meandering.

Further, in the radar cover 1 and the method of manufacturing the radar cover 1 of the present embodiment, the paint forming the paint layer 4 covers the entire print layer 3 except for the region where the emblem E is formed. Therefore, the print layer 3 can be protected by the paint layer 4 in a region other than the region where the emblem E is formed.

Further, in the method of manufacturing the radar cover 1 and the radar cover 1 of the present embodiment, the transparent member 2 has an inner core accommodating recess 2b in which the inner core 5 having a brilliant discontinuous film is accommodated as the recess 2a. The emblem E is formed by accommodating the inner core 5 in the inner core accommodating recess 2b. Therefore, it is possible to prevent the boundary line between the inner core 5 and the print layer 3 from unintentionally meandering.

Further, in the manufacturing method of the radar cover 1 of the present embodiment, the printing layer 3 which is a colored layer is formed by the printing method. Therefore, patterning of the colored layer can be easily and accurately performed.

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 colored layer is the print layer 3 has been described. However, the present invention is not limited to this, and it is also possible to form a colored layer by painting or the like.

Further, in the above embodiment, the configuration in which the transparent member 2 has the inner core accommodating recess 2b and the painted recess 2c as the recess 2a, and the painted recess 2c has the frame-shaped portion 2d and the mesh-shaped portion 2e has been described. .. However, the present invention is not limited to this, and any radar cover having a structure in which the transparent member has a recess having an inner wall surface connected to the colored layer forming region and a method for manufacturing the radar cover can be applied. Is possible.

Further, in the above embodiment, the configuration in which the inner core 5 is housed in the inner core accommodating recess 2b of the transparent member 2 and the inner core 5 is sandwiched between the transparent member 2 and the support member 6 to form the emblem E has been described. However, the present invention is not limited to this, for example, a radar cover having a configuration in which a brilliant discontinuous film is directly formed on the surface of the transparent member 2 and the support member 6 and the inner core 5 is omitted, and a radar cover thereof. It can also be applied to the manufacturing method.

1 ... Radar cover, 2 ... Transparent member, 2a ... Recessed part, 2b ... Inner core housing recess, 2c ... Painted recess, 2d ... Frame-shaped part, 2e ... Reticulated part, 3 ... Print layer (colored) Layer), 4 ... paint layer, 5 ... inner core, 6 ... support member, 10 ... mold, 11 ... cavity mold, 12 ... core mold, D ... outer design part, E ... Emblem, R …… Print layer formation area (colored layer formation area), X …… Radar unit

Claims (5)

A radar cover placed on the radio wave path of the radar unit that detects the surrounding conditions of the vehicle.
Between the transparent member, the support member joined to the back surface of the transparent member and supporting the transparent member, and formed on the surface of the transparent member on the support member side, and between the transparent member and the support member. With a colored layer to be placed,
The transparent member has a recess that is bent at an angle of 90 ° or more and 93 ° or less with respect to the colored layer forming region where the colored layer is formed to connect the inner wall surface.
The transparent member has, as the recess, a coating recess in which a paint having a color different from that of the colored layer is applied to the inner wall surface.
A radar cover characterized in that the paint covers the entire surface of the colored layer on the support member side. The radar cover according to claim 1, wherein the transparent member has, as the recess, an inner core accommodating recess in which an inner core having a brilliant discontinuous film is accommodated. It is a method of manufacturing a radar cover that is placed on the radio wave running path of the radar unit that detects the surrounding conditions of the vehicle.
The radar cover is formed on a transparent member, a support member that is joined to the back surface of the transparent member and supports the transparent member, and a surface of the transparent member on the support member side, and the transparent member and the support. With a colored layer arranged between the members,
A transparent member forming step of forming the transparent member having a recess to which the inner wall surface is connected by bending at an angle of 90 ° or more and 93 ° or less with respect to the colored layer forming region where the colored layer is formed.
A colored layer forming step of forming the colored layer in the colored layer forming region of the transparent member,
It has a support member forming step of covering the surface of the transparent member on the side of the colored layer forming region to form the support member.
In the colored layer forming step, the colored layer is formed by a printing method.
Prior to the support member forming step, a coating step of applying a paint having a color different from that of the colored layer is performed on at least a part of the inner wall surface of the recess.
A method for manufacturing a radar cover, characterized in that, in the coating step, the coating material is applied over the entire surface of the colored layer. The method for manufacturing a radar cover according to claim 3, further comprising an inner core installation step of accommodating an inner core having a brilliant discontinuous film in at least a part of the recess before the support member forming step. In the transparent member forming step, the transparent member is formed by injection molding using a cavity mold and a core mold.
The core mold has a base for forming the colored layer and a nest for forming the recess.
The radar cover according to claim 3 or 4, wherein the nest is separated from the base and projects from the surface of the base toward the cavity mold while being fixed to the base. Manufacturing method.

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