JP7076415B2 - Radar cover manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a radar cover and 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 the vehicle in a state of being covered from the front by a radar cover on which an identification mark such as an emblem is formed.

The radar cover needs to be able to transmit radio waves transmitted and received in the radar unit without attenuating them as much as possible. On the other hand, the radar cover is generally arranged at a position that is easily visible from the outside in front of the vehicle, and is therefore an important component that forms the appearance impression of the vehicle. For this reason, the radar cover is provided with identification marks such as emblems of vehicle manufacturers and patterns for enhancing the texture. Such identification marks and patterns are formed by patterning a colored layer made of a metal or paint capable of transmitting radio waves on the back surface of the transparent member.

Japanese Unexamined Patent Publication No. 2016-141355

By the way, when such a colored layer is patterned and formed on the back surface of the transparent member, a mask made of masking tape or a printing layer is formed on the back surface of the transparent member, and the colored layer is formed by superimposing the mask on the mask. ing. However, in such a case, an operator needs to attach a masking tape or the like to the formed transparent member or form a print layer, which complicates the manufacturing process of the radar cover. .. Further, when the back surface of the transparent member is uneven, it is difficult to attach a masking tape or the like or to form a print layer.

The present invention has been made in view of the above-mentioned problems, and in the radar cover manufacturing method and the radar cover, the back surface of the transparent member is formed without performing a step of forming a mask on the transparent member after the transparent member is formed. The purpose is to enable patterning of the colored layer provided in the above.

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

The first invention is a radar having a transparent member, a support member arranged on the back surface of the transparent member and supporting the transparent member, and a colored layer arranged between the transparent member and the support member. A method for manufacturing a cover, which is formed of a transparent member made of a resin and a resin different from the transparent member, and is provided in a patterned manner so as to expose a part of the transparent member on the back surface of the transparent member. An injection molding step of forming a mask resin layer by injection molding, a colored layer forming step of forming the colored layer on the back surface of the transparent member via the mask resin layer, and a mask resin layer from the transparent member. A structure is adopted in which a peeling step for peeling and a support member forming step for forming the support member on the back surface of the transparent member after the peeling step are provided.

In the second invention, in the first invention, the transparent member having a recess on the back surface and the mask resin layer patterned so as to expose the recess are formed in the injection molding step. The configuration is adopted.

In the third invention, in the first or second invention, in the colored layer forming step, a glossy layer having a gloss on the back surface of the transparent member via the mask resin layer is vacuum-deposited or vacuum-deposited as the colored layer. The configuration of forming by sputtering is adopted.

According to the fourth invention, in the first or second invention, the colored layer is formed by applying a paint to the back surface of the transparent member via the mask resin layer in the colored layer forming step. Adopt the configuration.

A fifth invention is a radar having a transparent member, a support member arranged on the back surface of the transparent member and supporting the transparent member, and a colored layer arranged between the transparent member and the support member. In the cover, the colored layer is fixed to the back surface of the transparent member, and the entire colored layer is exposed via the transparent member, so that the support member avoids the arrangement region of the colored layer. A configuration is adopted in which the material is exposed via the transparent member.

The sixth invention adopts the configuration in which the glossy layer having gloss is provided as the colored layer in the fifth invention.

The seventh invention adopts the configuration in which the paint layer formed by the paint is provided as the colored layer in the fifth or sixth invention.

According to the method for manufacturing a radar cover of the present invention, a transparent member is formed by an injection molding step with a patterned mask resin layer provided on the back surface. Therefore, the mask can be formed without attaching a masking tape or forming a print layer after forming the transparent member. Further, since the mask resin layer is formed of a resin material different from that of the transparent member, the boundary region between the mask resin layer and the transparent member can be clarified, and the mask resin layer can be accurately peeled off from the transparent member. .. The colored layer can be easily patterned by peeling the mask resin layer from the transparent member after the colored layer forming step. Therefore, according to the method for manufacturing a radar cover of the present invention, it is possible to pattern a colored layer provided on the back surface of a transparent member without performing a step of forming a mask on the transparent member after forming the transparent member. Become. Further, in the radar cover of the present invention, the colored layer is fixed to the back surface of the transparent member and the entire colored layer is exposed via the transparent member, and the support member is a transparent member while avoiding the arrangement region of the colored layer. Is exposed through. Such a radar cover of the present invention can be manufactured by the above-mentioned manufacturing method of the radar cover of the present invention.

(A) is a front view of the radiator grill provided with the radar cover according to the first embodiment of the present invention, and (b) is an enlarged front view of the radar cover according to the first embodiment of the present invention. It is sectional drawing of the radar cover in 1st Embodiment of this invention. It is a schematic diagram for demonstrating the manufacturing method of the radar cover in 1st Embodiment of this invention. It is sectional drawing of the radar cover in 2nd Embodiment of this invention. It is a schematic diagram for demonstrating the manufacturing method of the radar cover in 2nd Embodiment of this invention.

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

(First Embodiment)
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. As shown in FIG. 2, the radar cover 10 provides a bright region 10A representing a figure or a character indicating a recognition mark such as a vehicle manufacturer's emblem and visibility of the bright region 10A when viewed from the front side of the vehicle. It is a component having a black region 10B to be improved.

As shown in FIG. 2, such a radar cover 10 includes a transparent member 11, a brilliant film 12 (colored layer), and a base member 13 (support member). The transparent member 11 is a portion formed of a substantially rectangular transparent resin material arranged on the outermost side of the vehicle. The transparent member 11 has a smooth surface on the front side in order to enhance the visibility of the glitter film 12 from the outside of the vehicle. Further, on the back surface of the transparent member 11, a brilliant film forming recess 11a (recess) in which the brilliant film 12 is formed on the inner wall surface is formed.

The brilliant film 12 is formed on the inner wall surface of the brilliant film forming recess 11a, so that the brilliant film 12 can be three-dimensionally visible from the front side of the vehicle. The glitter film forming recess 11a is provided along the shape of a recognition mark such as an emblem of a vehicle manufacturer or a character. As shown in FIG. 2, the above-mentioned bright region 10A is formed by forming the bright film 12 on the inner wall surface of such a bright film forming recess 11a.

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 brilliant film 12 is a glossy layer made of a thin film having a metallic luster (metal color) fixed to the inner wall surface of the brilliant film forming recess 11a of the transparent member 11 and having radio wave transmission. The glitter film 12 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 12 may be a thin film formed of an alloy containing a semiconductor and a metal. Specifically, the glitter film 12 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 12 formed of such an alloy contains a semiconductor having less free electrons than a metal, and has a property of transmitting electromagnetic waves.

In the present embodiment, the glitter film 12 is provided only on the inner wall surface of the glitter film forming recess 11a, and the entire surface can be visually recognized via the transparent member 11. That is, the brilliant film 12 is fixed to the back surface of the transparent member 11, and the entire surface (the entire surface of the surface opposite to the base member 13) is exposed via the transparent member 11.

The base member 13 is a portion fixed (joined) to the side surface of the transparent member 11, and supports the transparent member 11 from the back surface side. 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. Further, the base member 13 has a convex portion 13b embedded in the glitter film forming recess 11a of the transparent member 11 on the surface on the transparent member 11 side.

Such a base member 13 is made of a black resin material, and is visible from the outside via the transparent member 11 except for the region where the glitter film 12 is formed. The black region 10B described above is formed by such a base member 13. That is, in the present embodiment, the base member 13 is exposed via the transparent member 11 while avoiding the arrangement region of the glitter film 12 (except for the arrangement region of the glitter film 12).

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 black PC, synthetic resin such as PET, or a composite resin thereof, and has a thickness of about 0.5 mm to 10 mm.

Subsequently, a method of manufacturing the radar cover 10 of the present embodiment will be described with reference to FIG. 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 provided with the mask resin layer 30 is formed.

The mask resin layer 30 is provided so as to expose the inner wall surface (a part of the transparent member 11) of the glitter film forming recess 11a provided on the back surface of the transparent member 11, and forms the glitter film 12. A layer that acts as a mask for the case. The mask resin layer 30 is patterned so as to have an opening for exposing the glitter film forming recess 11a, and is provided on the back surface of the transparent member 11.

The mask resin layer 30 is formed of a resin material different from that of the transparent member 11. For example, when the transparent member 11 is formed of PC, the mask resin layer 30 can be formed of polyvinyl chloride. By forming the mask resin layer 30 formed of polyvinyl chloride on the transparent member 11 formed by the PC in this way, the mask resin layer 30 can be easily peeled off from the transparent member 11.

Here, the transparent member 11 and the mask resin layer 30 are formed by injection molding. For example, the transparent member 11 and the mask resin layer 30 are formed by two-color molding in which the resin material to be the mask resin layer 30 is first injected into the mold, and then the resin material to be the transparent member 11 is injected into the same mold. Form a structure having. Such a step shown in FIG. 3A is formed of a transparent member 11 made of a resin and a resin different from the transparent member 11, and is patterned so as to expose a part of the transparent member 11 on the back surface of the transparent member 11. Corresponds to the injection molding step of forming the mask resin layer 30 provided by the injection molding.

Next, as shown in FIG. 3 (b), the glitter film 12 is formed. Here, the glitter film 12 is formed on the back surface of the glitter film forming recess 11a via the mask resin layer 30 by vacuum vapor deposition or sputtering. At this time, the inner wall surface of the glitter film forming recess 11a of the transparent member 11 is not covered by the mask resin layer 30, and is in an exposed state. Therefore, the brilliant film 12 is fixedly formed on the inner wall surface of the brilliant film forming recess 11a. Such a step shown in FIG. 3B is a bright film forming step (colored layer forming step) for forming the bright film 12 on the back surface of the transparent member 11 via the mask resin layer 30.

Next, as shown in FIG. 3C, the mask resin layer 30 is peeled off from the transparent member 11. Here, for example, a part of the mask resin layer 30 is picked up by a tool or the like, and the mask resin layer 30 is peeled from the transparent member 11 by pulling the mask resin layer 30 away from the transparent member 11. By peeling off the mask resin layer 30 in this way, the brilliant film 12 attached to the mask resin layer 30 is removed from the transparent member 11 together with the mask resin layer 30. As a result, in the present embodiment, the bright film 12 remains only on the inner wall surface of the bright film forming recess 11a on the back surface of the transparent member 11. Such a step shown in FIG. 3C corresponds to a peeling step of peeling the mask resin layer 30 from the transparent member 11.

Next, as shown in FIG. 3D, the base member 13 is formed. Here, the transparent member 11 on which the brilliant film 12 is formed is placed inside the mold, and the base member 13 is formed by insert molding (injection molding) in which the molten resin is injected onto the back surface side of the transparent member 11. Form. Such a base member 13 is welded to a region excluding the inner wall surface of the glitter film forming recess 11a on the back surface of the transparent member 11. Such a step shown in FIG. 3D corresponds to a base member forming step (support member forming step) in which the base member 13 is formed on the back surface of the transparent member 11.

The radar cover 10 of the present embodiment is manufactured by the above steps. According to the method of manufacturing the radar cover 10 of the present embodiment as described above, the transparent member 11 is formed by the injection molding step with the patterned mask resin layer 30 provided on the back surface. Therefore, the mask can be formed without attaching the masking tape or forming the print layer after the transparent member 11 is formed. Further, since the mask resin layer 30 is formed of a resin material different from that of the transparent member 11, the boundary region between the mask resin layer 30 and the transparent member 11 is clarified, and the mask resin layer 30 is accurately peeled off from the transparent member 11. It becomes possible. By peeling the mask resin layer 30 from the transparent member 11 after the glitter film forming step, the glitter film 12 can be easily patterned.

Therefore, according to the method for manufacturing the radar cover 10 of the present embodiment, the glitter film 12 provided on the back surface of the transparent member 11 without performing the step of forming a mask on the transparent member 11 after the transparent member 11 is formed. Can be patterned.

Further, in the radar cover 10 of the present embodiment, the glitter film 12 is fixed to the back surface of the transparent member 11, and the entire glitter film 12 is exposed via the transparent member 11. The base member 13 is exposed via the transparent member 11 while avoiding the arrangement area. Such a radar cover 10 of this embodiment can be manufactured by the above-mentioned manufacturing method of the radar cover 10. Further, according to the radar cover 10 of the present embodiment, since the glitter film 12 can be formed only on the portion visually recognizable from the outside, it is not necessary to leave a mask that partially hides the glitter film 12. .. Therefore, it is possible to secure a wide surface to which the transparent member 11 and the base member 13 are fixed, and it is possible to improve the adhesion between the transparent member 11 and the base member 13.

Further, in the method for manufacturing the radar cover 10 of the present embodiment, the glitter film forming recess 11a is provided on the back surface of the transparent member 11, and the mask resin layer 30 is provided so that the inner wall surface of the glitter film forming recess 11a is exposed. Was formed. Therefore, the bright film 12 is formed on the inner wall surface of the bright film forming recess 11a, and it is possible to give a three-dimensional effect to the bright region 10A.

Further, as described above, according to the method for manufacturing the radar cover 10 of the present embodiment, as described above, the mask can be used without attaching a masking tape or forming a printing layer after forming the transparent member 11. Can be formed. Therefore, for example, even if the back surface of the transparent member 11 is provided with an uneven portion on which it is difficult to attach a masking tape or form a print layer, a mask (mask resin layer 30) can be easily formed on the uneven portion. Can be done. Therefore, it is possible to use a radar cover with a design different from the conventional one.

(Second Embodiment)
Next, the second embodiment of the present invention will be described with reference to FIGS. 4 and 5. In the description of the present embodiment, the same parts as those of the first embodiment will be omitted or simplified.

FIG. 4 is a cross-sectional view of the radar cover 20 of the present embodiment. As shown in this figure, in the present embodiment, the glitter film 12 is not directly provided in the glitter film forming recess 11a of the transparent member 11, and the inner core 14 having the glitter film is accommodated. ing. Further, on the back surface of the transparent member 11, in addition to the glitter film forming recess 11a, a decorative layer forming recess 11b (recess) for forming the decorative layer 15 (colored layer) is formed. These decorative layer forming recesses 11b are shallower than the glitter film forming recesses 11a. The decorative layer forming recess 11b makes the decorative layer 15 formed on the inner wall surface three-dimensionally visible from the front side of the vehicle. In the present embodiment, the decorative layer 15 is formed on the inner wall surface of the decorative layer forming recess 11b, so that the decorative region 10C is formed on the outside of the bright region 10A. For example, such a decorative region 10C forms a pattern with respect to the periphery of the bright region 10A.

The decorative layer 15 is formed on the entire inner wall surface of the decorative layer forming recess 11b provided on the back surface of the transparent member 11. Such a decorative layer 15 is formed by a coating film formed by drying the paint. That is, in the present embodiment, the decorative layer 15 is a coating film formed by the paint. Such a decorative layer 15 has a different color from the base member 13.

In the present embodiment, the decorative layer 15 is provided only on the inner wall surface of the decorative layer forming recess 11b, and the entire decorative layer 15 can be visually recognized via the transparent member 11. That is, the decorative layer 15 is fixed to the back surface of the transparent member 11, and the entire surface (the entire surface of the surface opposite to the base member 13) is exposed via the transparent member 11.

Subsequently, a method of manufacturing the radar cover 20 of the present embodiment will be described with reference to FIG. FIG. 5 is a schematic diagram for explaining a method of manufacturing the radar cover 20 of the present embodiment. First, as shown in FIG. 5A, the transparent member 11 provided with the mask resin layer 30 is formed. In the present embodiment, the mask resin layer 30 is provided so as to expose the inner wall surface of the decorative layer forming recess 11b provided on the back surface of the transparent member 11, and when the decorative layer 15 is formed. Functions as a mask. That is, in the present embodiment, the mask resin layer 30 is patterned so as to have an opening for exposing the decorative layer forming recess 11b, and is provided on the back surface of the transparent member 11.

Next, as shown in FIG. 5B, the decorative layer 15 is formed. Here, the paint that is the forming material of the decorative layer 15 is applied to the back surface of the transparent member 11 via the mask resin layer 30. Then, by drying the applied paint, the decorative layer 15 made of the paint layer is formed. Such a decorative layer 15 comes into direct contact with the transparent member 11 only in the decorative layer forming recess 11b. Such a step shown in FIG. 5B is a decorative layer forming step (colored layer forming step) for forming the decorative layer 15 on the back surface of the transparent member 11 via the mask resin layer 30.

Next, as shown in FIG. 5C, the mask resin layer 30 is peeled off from the transparent member 11. By peeling off the mask resin layer 30 in this way, the decorative layer 15 attached to the mask resin layer 30 is removed from the transparent member 11 together with the mask resin layer 30. As a result, in the present embodiment, the decorative layer 15 remains only on the inner wall surface of the decorative layer forming recess 11b on the back surface of the transparent member 11.

Next, as shown in FIG. 5D, the inner core 14 on which the bright film is formed is housed in the bright film forming recess 11a. Next, as shown in FIG. 5 (e), the base member 13 is formed.

According to the manufacturing method of the radar cover 20 of the present embodiment as described above, the transparent member 11 is formed by the injection molding step with the patterned mask resin layer 30 provided on the back surface. Therefore, the mask can be formed without attaching the masking tape or forming the print layer after the transparent member 11 is formed. Further, since the mask resin layer 30 is formed of a resin material different from that of the transparent member 11, the boundary region between the mask resin layer 30 and the transparent member 11 is clarified, and the mask resin layer 30 is accurately peeled off from the transparent member 11. It becomes possible. The decorative layer 15 can be easily patterned by peeling the mask resin layer 30 from the transparent member 11 after the decorative layer forming step.

Therefore, according to the method for manufacturing the radar cover 20 of the present embodiment, the decorative layer 15 provided on the back surface of the transparent member 11 without performing the step of forming a mask on the transparent member 11 after the transparent member 11 is formed. Can be patterned.

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, in the injection molding step, it is also possible to adopt a configuration in which the mask resin layer 30 is provided with a protruding portion so as to protrude in a direction away from the transparent member 11. By adopting such a configuration, the mask resin layer 30 can be easily peeled from the transparent member 11 by pinching the protruding portion of the mask resin layer 30 in the later peeling step.

Further, in the first embodiment, the configuration for forming the brilliant film 12 with respect to the inner wall surface of the brilliant film forming recess 11a has been described. Further, in the second embodiment, the configuration for forming the decorative layer 15 with respect to the inner wall surface of the decorative layer forming recess 11b has been described. However, the present invention is not limited to this, and it is also possible to adopt a configuration in which the glitter film 12 and the decorative layer 15 are formed in a part of the back surface of the transparent member 11 other than the recess.

1 ... Radiator grill, 10 ... Radar cover, 11 ... Transparent member, 11a ... Bright film forming recess (recess), 11b ... Decorative layer forming recess (recess), 12 ... Bright film (colored) Layer), 13 ... Base member (support member), 14 ... Inner core, 15 ... Decorative layer (colored layer), 20 ... Radar cover, 30 ... Mask resin layer, R ... Radar unit

Claims (4)

A method for manufacturing a radar cover having a transparent member, a support member arranged on the back surface of the transparent member and supporting the transparent member, and a colored layer arranged between the transparent member and the support member. hand,
Injection molding is performed on the transparent member made of a resin and a mask resin layer formed of a resin different from the transparent member and patterned on the back surface of the transparent member so as to expose a part of the transparent member. And the injection molding process formed by
A colored layer forming step of forming the colored layer on the back surface of the transparent member via the mask resin layer, and
A peeling step of peeling the mask resin layer from the transparent member,
It has a support member forming step of forming the support member on the back surface of the transparent member after the peeling step.
In the injection molding step, the mask resin layer is provided with a protruding portion that protrudes in a direction away from the transparent member.
In the peeling step, the protruding portion is picked and the mask resin layer is peeled from the transparent member.
A method of manufacturing a radar cover, which is characterized by this. The radar cover according to claim 1, wherein in the injection molding step, the transparent member provided with a recess on the back surface and the mask resin layer patterned so as to expose the recess are formed. Production method. The first or second aspect of the present invention, wherein in the colored layer forming step, a glossy layer having a gloss on the back surface of the transparent member is formed as the colored layer by vacuum vapor deposition or sputtering through the mask resin layer. How to make a radar cover. The method for manufacturing a radar cover according to claim 1 or 2, wherein in the colored layer forming step, the colored layer is formed by applying a paint to the back surface of the transparent member via the mask resin layer. ..

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