JP6809886B2 - 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, a radar unit that detects obstacles and the like around the vehicle using radio waves such as millimeter waves has been mounted on the vehicle. Such a radar unit is attached to the vehicle in a state where at least a part of the members is covered with a radar cover made of a resin capable of transmitting radio waves. The members constituting such a radar cover are generally formed by injection molding in which a molten resin is injected into the mold. For example, Patent Document 1 discloses a method for manufacturing a radar cover in which a transparent member forming a surface side of a radar cover and a support member supporting the transparent member are formed by injection molding.

Japanese Unexamined Patent Publication No. 2016-150497

By the way, in the radar cover as described above, when a colored layer is formed between the transparent member and the supporting member, the colored layer can be visually recognized from the outside through the transparent member, and the emblem or pattern is formed by the colored layer. Can be formed. On the other hand, for example, in consideration of the design and mountability of the radar cover, a shape in which the outer edge portion of the transparent member projects laterally from the support member may be adopted. In such a case, a region not covered by the support member is generated in a part (outer edge portion) of the back surface of the transparent member on which the colored layer is formed. In such a region, the colored layer is exposed, and the deterioration of the colored layer may be accelerated. Deterioration of the colored layer causes discoloration of the emblem or pattern formed by the colored layer, and may greatly affect the formation of the appearance impression of the vehicle.

The present invention has been made in view of the above-mentioned problems, and in a radar cover in which a support member is joined to the back surface of a transparent member, deterioration of a colored layer not covered by the support member at the outer edge of the transparent member is deteriorated. The purpose is to suppress it.

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 path of a radar unit for detecting the surrounding condition of a vehicle, wherein a plate-shaped transparent member made of resin and a back side of an outer edge portion of the transparent member are provided. A support member joined to the back surface of the transparent member with at least a part exposed, and a colored layer formed at least on the back surface side of the outer edge portion of the transparent member and not covered by the support member. , A configuration is adopted in which a coating film that covers the colored layer is provided in a region that is not covered by the support member.

The second invention adopts the configuration in which the thickness dimension of the coating film is smaller than the thickness dimension of the support member in the first invention.

The third invention adopts the configuration in which the coating film is formed of the same material as the support member in the first or second invention.

A fourth invention is a method for manufacturing a radar cover arranged on a path of radio waves of a radar unit for detecting the surrounding condition of a vehicle, which comprises a transparent member forming step of forming a plate-shaped transparent member made of resin. A color layer forming step of forming a colored layer including an outer edge portion of the transparent member on the back surface side of the transparent member, and a back surface of the transparent member with at least a part of the back surface side of the outer edge portion of the transparent member exposed. Adopted a configuration having a support member forming step of forming a support member joined to the above, and a coating film forming step of forming a coating film covering the colored layer in a region not covered by the support member. To do.

In the fifth aspect of the invention, in the fourth invention, in the coating film forming step, a mold is arranged so as to face each other with a gap between the coating film and the colored layer in the region where the coating film is formed. Then, the gap is filled with the molten resin to form the coating film.

In the sixth invention, in the fifth invention, the configuration in which the coating film forming step is performed in the same step as the supporting member forming step is adopted.

According to the present invention, it has a coating film that covers a colored layer in a region that is not covered by a support member at the outer edge of the transparent member. Therefore, the coating film can prevent the colored layer from being exposed even in the region not covered by the support member, and the colored layer can be protected. Therefore, according to the present invention, in the radar cover in which the support member is joined to the back surface of the transparent member, it is possible to suppress the deterioration of the colored layer that is not covered by the support member at the outer edge portion of the transparent member.

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. It is an enlarged sectional view including a part of the coating film provided in 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. It is a schematic diagram for demonstrating the manufacturing method of the radar cover in one Embodiment of this invention. It is an enlarged cross-sectional view including the region which forms a coating film in 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 path of the radio wave of the radar unit X (the region where the radio wave emitted from the radar unit X is propagated), and is arranged in FIGS. 2 (a) and 2 (a). As shown in b), the transparent member 2, the printing layer 3, the paint layer 4 (colored layer), the inner core 5, the support member 6, and the coating film 7 are provided. In the radar cover 1 of the present embodiment, the engaging portion 6a integrally formed with the support member 6 is engaged with the mounting seat portion (two-dot chain line Y in the drawing) formed on the radiator grill side. It is attached to the radiator grill by combining. Further, the radiator grill is attached to the vehicle body.

The transparent member 2 is formed of a transparent resin material in a plate shape, 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 dug toward the surface side is formed on the back surface (the surface on the support member 6 side) of the transparent member 2. 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.

Further, in the radar cover 1 of the present embodiment, the transparent member 2 is formed larger than the support member 6 when viewed from the front side, and the outer edge portion projects from the support member 6. That is, the back surface side of the outer edge portion of the transparent member 2 is not covered by the support member 6. This is because the radar cover 1 including the transparent member 2 is partially overlapped with the radiator grille mounting seat Y and the transparent member 2 as shown, rather than being mounted so as to be immersed in the radiator grille mounting portion opening. However, mounting the transparent member 2 so that it protrudes from the front surface (left side of the paper surface) of the mounting surface gives a better design appearance.

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 paint 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.

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 on which the print layer 3 is formed. 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.

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. Further, the paint layer 4 is formed so as to cover a region on the back surface side of the outer edge portion of the transparent member 2 which is not covered by the support member 6. 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 vapor 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. In the present embodiment, the support member 6 is smaller than the transparent member 2 when viewed from the front, and is joined to the back surface of the transparent member 2 with the back surface side of the outer edge portion of the transparent member 2 exposed. Further, the support member 6 has an engaging portion 6a protruding 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.

FIG. 3 is an enlarged cross-sectional view including a part of the coating film 7. As shown in this figure, as shown in FIG. 2, the coating film 7 is provided in a region Ra on the back surface side of the outer edge portion of the transparent member 2 and not covered by the support member 6. The coating film 7 is provided so as to cover the coating layer 4 in the region Ra not covered by the support member 6 so as to be overlapped with the coating layer 4. Such a coating film 7 is set to have a smaller thickness dimension (dimension in the direction perpendicular to the surface of the transparent member 2) than the support member 6, and is provided with an engaging portion 6a of the support member 6. It is set to be less than a fraction (for example, one-third) of the thickness dimension of the non-existent region. Further, the coating film 7 is formed of the same material as the support member 6, and is integrally provided on the support member 6. Such a coating film 7 prevents the coating film 4 from coming into contact with outside air or rainwater, and prevents the coating film 4 from deteriorating. Further, even if the mounting seat Y of the radiator grill may hit the transparent member 2 due to vibration during vehicle running after the radar cover 1 is mounted on the radiator grill (vehicle), the coating film 7 is interposed between the two. Therefore, the paint layer 4 is not peeled off, and the appearance quality of the radar cover 1 can be kept good for a long period of time.

Subsequently, the manufacturing method of the radar cover 1 of the present embodiment will be described with reference to FIGS. 4 to 9.

First, as shown in FIG. 4, the transparent member 2 is formed. 4 (a) is a cross-sectional view at the same position as FIG. 2 (a), and FIG. 4 (b) is a cross-sectional view at the same position as FIG. 2 (b). 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. 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. Such a step shown in FIG. 4 is a step of forming a plate-shaped transparent member 2 made of resin, and corresponds to a transparent member forming step of the present invention.

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. ..

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 forming a paint layer 4 which is a colored layer including the outer edge portion of the transparent member 2 on the back surface side of the transparent member 2, and corresponds to the colored layer forming step 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 bright 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.

Subsequently, as shown in FIG. 8, the support member 6 and the coating film 7 are 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, an insert in which the transparent member 2 in which the inner core 5 is installed in the inner core accommodating recess 2b is arranged inside the insert molding die 20 (see FIG. 9), and the molten resin is injected onto the back side of the transparent member 2. By performing molding, 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.

Further, when insert molding is performed, as shown in the enlarged view of FIG. 9, the coating film 7 forms the core mold 22 of the insert molding mold 20 having the cavity mold 21 and the core mold 22. In the formed region, a gap S is provided between the paint layer 4 and the paint layer 4. Then, the coating film 7 is formed by filling the gap S with the molten resin. That is, in the present embodiment, the coating film 7 is formed in the same process as the support member 6.

Such steps shown in FIGS. 8 and 9 are steps of forming the support member 6 joined to the back surface of the transparent member 2 with the back surface side of the outer edge portion of the transparent member 2 exposed, and the support member. This is a step of forming a coating film 7 that covers the coating layer 4 in a region not covered by 6. That is, the steps shown in FIGS. 8 and 9 are the support member forming step of the present invention and correspond to the coating film 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 coating film 7 covers the paint layer 4 in the region Ra not covered by the support member 6 at the outer edge of the transparent member 2. Cover. Therefore, the coating film 7 can prevent the paint layer 4 from being exposed even in the region Ra that is not covered by the support member 6, and the paint layer 4 can be protected. Therefore, according to the method of manufacturing the radar cover 1 and the radar cover 1 of the present invention of the present embodiment, it is possible to suppress deterioration of the paint layer 4 which is not covered by the support member 6 at the outer edge portion of the transparent member 2. It becomes.

Further, in the radar cover 1 of the present embodiment, the thickness dimension of the coating film 7 is set to be smaller than the thickness dimension of the support member 6. That is, in the radar cover 1 of the present embodiment, the coating film 7 is formed thinner than the support member 6. Therefore, the coating film 7 can be formed with the minimum amount of forming material, and the radar cover 1 can be made smaller and lighter.

Further, in the radar cover 1 of the present embodiment, the coating film 7 is formed of the same material as the support member 6. Therefore, the support member 6 and the coating film 7 can be integrally formed, and the coating film 7 can be firmly fixed to the support member 6. Therefore, it is possible to prevent the coating film 7 from peeling off due to deterioration over time or the like.

Further, in the method for manufacturing the radar cover 1 of the present embodiment, the core mold 22 is arranged so as to face the paint layer 4 with a gap S in the region where the coating film 7 is formed. S was filled with a molten resin to form a coating film 7. Therefore, the coating film 7 can be easily formed, and the core mold 22 does not come into direct contact with the paint layer 4, and the core mold 22 comes into contact with the paint layer 4. It is possible to prevent peeling of the layer 4 and the like.

Further, in the method of manufacturing the radar cover 1 of the present embodiment, the support member 6 and the coating film 7 are formed in the same process. Therefore, the man-hours for manufacturing the radar cover 1 can be reduced, and the radar cover 1 can be manufactured in a short time and at low cost.

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 of the present invention is the paint layer 4 has been described. However, the present invention is not limited to this, and for example, the print layer 3 can be formed up to the back surface side of the outer edge portion of the transparent member 2, and the print layer 3 can be used as the colored layer of the present invention. .. Further, the color of the colored layer is not particularly limited.

Further, in the above embodiment, the configuration in which the paint layer 4 which is a colored layer is formed on the entire circumference of the outer edge portion of the transparent member 2 has been described. However, the present invention is not limited to this, and it is also possible to adopt a configuration in which a colored layer is formed only on a part of the outer edge portion of the transparent member 2.

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, 3 ... Print layer, 4 ... Paint layer (colored layer), 5 ... Inner core, 6 ... Support member, 7 ... Coating film, 10 ... Gold Die, 11 ... Cavity mold, 12 ... Core mold, 20 ... Insert mold, 21 ... Cavity mold, 22 ... Core mold (mold), D ... Outer design part, E …… Emblem, X …… Radar unit

Claims (4)

A radar cover placed on the radio wave path of the radar unit that detects the surrounding conditions of the vehicle.
A plate-shaped transparent member made of resin and
A support member joined to the back surface of the transparent member with at least a part exposed on the back surface side of the outer edge portion of the transparent member.
A colored layer formed at least on the back surface side of the outer edge portion of the transparent member and not covered by the support member.
The colored layer is directly coated in the region not covered by the support member and has a coating film of a member different from the support member .
The colored layer is a radar cover characterized by being a paint layer formed by drying a paint. The radar cover according to claim 1, wherein the thickness dimension of the coating film is smaller than the thickness dimension of the support member. It is a method of manufacturing a radar cover that is placed on the radio wave path of the radar unit that detects the surrounding conditions of the vehicle.
A transparent member forming process for forming a plate-shaped transparent member made of resin,
A colored layer forming step of forming a colored layer on the back surface side of the transparent member including the outer edge portion of the transparent member,
A support member forming step of forming a support member joined to the back surface of the transparent member with at least a part of the back surface side of the outer edge portion of the transparent member exposed.
It has a coating film forming step of forming a coating film that directly coats the colored layer in a region not covered by the support member as a member different from the support member .
A method for manufacturing a radar cover, which comprises forming the colored layer composed of the paint layer by drying the paint in the colored layer forming step. In the coating film forming step, a mold is arranged so as to face the colored layer with a gap in the region where the coating film is formed, and the gap is filled with molten resin to cover the cover. The method for manufacturing a radar cover according to claim 3, wherein a cover film is formed.

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