WO2022168602A1 - 積層構造体及び対象物検知構造 - Google Patents
積層構造体及び対象物検知構造 Download PDFInfo
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- WO2022168602A1 WO2022168602A1 PCT/JP2022/001657 JP2022001657W WO2022168602A1 WO 2022168602 A1 WO2022168602 A1 WO 2022168602A1 JP 2022001657 W JP2022001657 W JP 2022001657W WO 2022168602 A1 WO2022168602 A1 WO 2022168602A1
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- outer member
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Definitions
- the present disclosure relates to laminated structures and object sensing structures.
- Japanese Patent Application Laid-Open No. 2003-019765 describes a metallic paint film in which an undercoat film and a metal layer are coated in this order on a substrate, and a clear paint film is coated on the metal layer, and this metallic paint film is It is disclosed for use in automotive parts.
- the automatic collision avoidance system automatically applies the brakes using the image data from the vehicle-mounted camera and the information about the relative distance to the object from the millimeter-wave radar.
- a laminated structure in which a plurality of members such as an inner member and an outer member are laminated is used for automobile emblems and the like.
- the laminated structure is manufactured by insert molding for the purpose of eliminating gaps between members and reducing transmission attenuation.
- the metal layer is damaged by high temperature, high pressure, etc. in the insert molding, and the deterioration of the appearance of the laminated structure becomes a problem, which may impair the design of the product.
- a protective film or the like is provided on the inner member or the outer member.
- the present disclosure has been made in view of the above circumstances, and aims to provide a laminated structure with excellent appearance and an object detection structure including the same.
- a laminated structure comprising an outer member having a recessed portion, a metal layer, and an inner member having a protruding portion that is fitted with the recessed portion to form a fitting portion, in this order.
- the laminated structure according to ⁇ 1> above which has a region surrounded by the fitting portion.
- the metal layer includes a silver particle layer, ⁇ The laminated structure according to any one of 1> to ⁇ 3>.
- ⁇ 5> The laminated structure according to any one of ⁇ 1> to ⁇ 4>, wherein the metal layer has a sea-island structure in which metal particles are scattered in islands.
- ⁇ 6> The laminated structure according to any one of ⁇ 1> to ⁇ 5> above, which is used as an exterior member of a moving object.
- An object detection structure comprising: the laminated structure according to any one of ⁇ 1> to ⁇ 6>above; and a millimeter wave radar for radiating millimeter waves toward the laminated structure.
- FIG. 1 is a schematic top view showing an example of the laminated structure of the present disclosure.
- FIG. 2 is a schematic cross-sectional view of the laminated structure shown in FIG. 1 taken along line AA.
- FIG. 3 is a schematic top view showing another example of the laminated structure of the present disclosure.
- FIG. 4 is a schematic cross-sectional view for explaining an example of the manufacturing method of the laminated structure of the present disclosure.
- FIG. 5 is a schematic cross-sectional view for explaining an example of the manufacturing method of the laminated structure of the present disclosure.
- FIG. 6 is a schematic cross-sectional view for explaining an example of the manufacturing method of the laminated structure of the present disclosure.
- 7 is a schematic cross-sectional view showing an outer member used in Example 1.
- FIG. 8 is a schematic cross-sectional view showing the inner member used in Example 1.
- FIG. 9 is a schematic cross-sectional view showing an outer member having a metal layer used in Example 1.
- the numerical range indicated using "-" includes the numerical values before and after "-" as the minimum and maximum values, respectively.
- the upper limit or lower limit of one numerical range may be replaced with the upper or lower limit of another numerical range described step by step.
- the upper or lower limits of the numerical ranges may be replaced with the values shown in the examples.
- each component may contain multiple types of applicable substances.
- the particles corresponding to each component may include multiple types of particles.
- the term “layer” or “film” refers to the case where the layer or film is formed in the entire region when observing the region where the layer or film is present, and only a part of the region. It also includes the case where it is formed.
- the thickness of each layer refers to the arithmetic mean value obtained by preparing a test piece from the object to be measured using a microtome or the like and measuring the thickness at any five points with an electron microscope.
- (meth)acryl is a term used as a concept that includes both acryl and methacryl.
- the term “process” includes a process that is independent of other processes, and even if the purpose of the process is achieved even if it cannot be clearly distinguished from other processes. .
- a laminated structure of the present disclosure includes, in this order, an outer member having a recessed portion, a metal layer, and an inner member having a protruding portion that fits into the recessed portion to form a fitting portion.
- the laminated structure of the present disclosure has excellent appearance.
- the reason for this is presumed as follows. As will be described later, the laminated structure of the present disclosure can be manufactured without using insert molding. Therefore, it is presumed that the metal layer is less damaged during the manufacturing process, and the laminate structure including the metal layer has an excellent appearance.
- the difference between the value of the relative permittivity of the member with the maximum relative permittivity and the value of the relative permittivity of the member with the minimum relative permittivity reduces the transmission attenuation of millimeter waves.
- 1.0 or less is preferable, 0.5 or less is more preferable, and 0.3 or less is still more preferable from the viewpoint of doing.
- the lower limit of the aforementioned difference is not particularly limited.
- all dielectric constants refer to values at 77 GHz.
- inventions of the laminated structure of the present disclosure include, for example, exterior members, and more specifically, exterior members for mobile bodies.
- moving bodies include automobiles such as four-wheeled vehicles and two-wheeled vehicles, trains, carts, ships, aircraft, bicycles, trolleys, trunks with casters, robots, drones, and electronic devices.
- Exterior parts include automobile parts such as emblems, bumpers, and grills.
- FIG. 1 is a schematic top view showing an example of the laminated structure 10
- FIG. 2 is a schematic cross-sectional view of the laminated structure 10 taken along line AA shown in FIG.
- the laminated structure 10 includes an outer member 1 having a concave portion 1A, a metal layer 2, and an inner member having a convex portion 3A which is fitted with the concave portion 1A to form a fitting portion. and a member 3 are provided in this order.
- millimeter waves pass through the laminated structure 10 as indicated by arrows in FIG. In FIG.
- the fitting portion 4 where the concave portion 1A and the convex portion 3A are fitted together is indicated by a dotted line. Further, in FIG. 2, the width of the convex portion and the concave portion forming the fitting portion is indicated by l, and the height of the fitting portion is indicated by h.
- the laminated structure 10 preferably has a region (hereinafter also referred to as a specific region) surrounded by the outer peripheral edge of the fitting portion 4 .
- FIG. 1 shows that the specific region follows the shape of the laminated structure 10, it is not limited to this and may not follow the shape. Since the laminated structure has the specific region, the airtightness between the outer member and the inner member tends to be improved, and deterioration over time of the metal layer or the like in the specific region can be suppressed.
- the laminated structure 10 is not limited to the form shown in FIG. 1, and as shown in FIG. may have been In FIG. 4, the laminated structure is indicated by reference numeral 30, the outer member is indicated by reference numeral 21, and the fitting portion is indicated by reference numeral 24. As shown in FIG.
- the inner peripheral edge of the fitting portion is provided at a position within 3 mm from the outer peripheral edge of the laminated structure.
- the outer peripheral end portion of the laminated structure means the end portion of the outer member or the outer member, whichever has the smaller area.
- d indicates the distance between the inner peripheral edge of the fitting portion and the outer peripheral edge of the laminated structure.
- the width l of the convex portion and the concave portion forming the mating portion is preferably 0.5 mm to 2.0 mm, more preferably 1.0 mm to 1.5 mm. It is more preferable to have Moreover, from the viewpoint of airtightness and strength of the mating portion, the height h of the mating portion is preferably 0.1 mm to 1.0 mm, more preferably 0.3 mm to 0.8 mm.
- a laminated structure of the present disclosure comprises an outer member having a concave portion.
- the shape of the concave portion is not particularly limited, and as shown in FIG. 1, the cross section may be substantially rectangular.
- the outer member can contain one or more resin materials.
- the resin material contained in the outer member include thermosetting resins and thermoplastic resins.
- Thermoplastic resins include polyethylene, polypropylene, polycarbonate (PC), polystyrene, polyvinyl chloride, vinyl polymers, polyesters, polyamides, acrylonitrile-butadiene-styrene copolymer resins (ABS resins), (meth)acrylic resins, acrylonitrile- Ethylene-propylene-diene-styrene copolymer resins (AES resins), thermoplastic elastomers and the like can be mentioned.
- the thermoplastic resin is preferably at least one resin selected from the group consisting of polycarbonate, ABS resin, (meth)acrylic resin and AES resin.
- the (meth)acrylic resin preferably contains a polymethyl methacrylate (PMMA) resin.
- Thermosetting resins include silicone resins, urethane resins, melamine resins, epoxy resins, phenol resins, and urea resins.
- the resin material is preferably selected from the group consisting of PC, ABS resin, (meth)acrylic resin and AES resin, with polycarbonate being particularly preferred.
- resin materials polypropylene has a light specific gravity, is easy to process, has high tensile strength, impact strength and compression strength, and is also excellent in weather resistance and heat resistance.
- ABS resin is relatively easy to apply surface treatment, and therefore, it is easy to apply coating after molding.
- PC has high impact resistance, excellent weather resistance and heat resistance, and excellent transparency.
- polycarbonate is easy to process, relatively light among plastic materials, and is a durable material.
- the outer member may contain additives such as inorganic particles, colorants, and ultraviolet absorbers within the range that does not impair the characteristics of the laminated structure of the present disclosure.
- the wavelength of the laser with which the outer member is irradiated varies depending on the laser irradiation device used, etc.
- the laser transmittance of the outer member is preferably 30% or more, more preferably 60% or more, and 90%. % or more is more preferable.
- a laser for example, a laser having a wavelength of 800 nm to 1100 nm can be used.
- the dielectric constant of the outer member at 77 GHz may be 2.5 to 3.0, 2.5 to 2.9, or 2.5 to 2.8.
- the dielectric loss tangent of the outer member is preferably 0.010 or less from the viewpoint of transmission of radio waves such as millimeter waves. Note that the lower limit of the dielectric loss tangent is not particularly limited.
- the thickness of the outer member can be appropriately designed according to the application of the laminated structure.
- the shape of the outer member is also not particularly limited.
- the laminated structure of the present disclosure includes an inner member facing the outer member and having a convex portion that fits with a concave portion of the outer member.
- the shape of the convex portion in the fitting portion is not particularly limited, it is preferable to have a shape along the shape of the concave portion.
- the inner member can contain one or more resin materials.
- the resin material contained in the inner member include thermosetting resins and thermoplastic resins. Since the thermosetting resin and the thermoplastic resin are as described above, their description is omitted here. Moreover, since the preferable resin material is the same as that of the outer member, description thereof is omitted here.
- the inner member may contain additives such as inorganic particles, colorants, and ultraviolet absorbers within a range that does not impair the characteristics of the laminated structure of the present disclosure.
- the wavelength of the laser with which the inner member is irradiated differs depending on the laser irradiation device used.
- the laser transmittance of the inner member is preferably 30% or less, more preferably 10% or less.
- the dielectric constant of the inner member at 77 GHz may be 2.5 to 3.0, 2.5 to 2.9, or 2.5 to 2.8.
- the dielectric loss tangent of the inner member is preferably 0.010 or less from the viewpoint of transmission of radio waves such as millimeter waves. Note that the lower limit of the dielectric loss tangent is not particularly limited.
- the thickness of the inner member can be appropriately designed according to the application of the laminated structure.
- the shape of the inner member is also not particularly limited.
- the laminated structure of the present disclosure comprises a metal layer between the outer member and the inner member.
- the metal layer may be, for example, a metal particle layer containing metal particles or a silver particle layer containing silver particles. Moreover, the metal particle layer may have a sea-island structure in which metal particles are scattered in islands.
- the thickness of the metal layer is not particularly limited, and is preferably about 30 nm to 200 nm.
- the proportion of silver particles in the silver particle layer is preferably 70% or less, preferably 60% to 65%, when the cross section of the silver particle layer is observed in the thickness direction. % is more preferred.
- the proportion of silver particles in the silver particle layer is 70% or less, the transmittance of millimeter wave radar tends to be further improved.
- the ratio of silver particles in the silver particle layer refers to a value measured as follows.
- a transmission electron micrograph is taken at a magnification of 300,000 times for a cross section in the thickness direction of the silver particle layer in the laminated structure.
- a center line passing through the center of the silver particle layer in the thickness direction is determined for the obtained electron micrograph.
- the length of the portion where the central line and the silver particles overlap is determined.
- the percentage of the value obtained by dividing the length of the portion where the central line and the silver particles overlap by the length of the entire central line is defined as the proportion of the silver particles in the silver particle layer.
- the surface resistivity of the silver particle layer is preferably 10 7 ⁇ / ⁇ or more, more preferably 5 ⁇ 10 7 ⁇ / ⁇ or more. This tends to result in a state in which an appropriate gap is formed between the silver particles that constitute the silver particle layer, and the laminated structure of the present disclosure tends to be excellent in millimeter wave transmittance.
- the upper limit of the surface resistivity of the silver particle layer is not particularly limited.
- the surface resistivity of the silver particle layer refers to a value measured according to JIS K6911:2006.
- undercoat layer From the viewpoint of improving the adhesion between the outer member or the inner member and the silver particle layer and from the viewpoint of forming a smooth surface on the outer member or the inner member, an undercoat is provided between the outer member or the inner member and the silver particle layer. Layers may be provided.
- fluorine resin paint for forming the undercoat layer, fluorine resin paint, polyester resin paint, epoxy resin paint, melamine resin paint, silicone resin paint, acrylic silicone resin paint, acrylic urethane resin paint, etc. may be used. It is preferable to use a urethane resin paint.
- the acrylic silicone resin coating has excellent adhesion to outer members or inner members, high gloss retention and color retention, and excellent chemical resistance, oil resistance, and water resistance.
- the acrylic urethane resin coating has a soft coating film, excellent adhesion, durability, weather resistance and chemical resistance. These resin paints may be used singly or in combination of two or more.
- the thickness of the undercoat layer is not particularly limited, and from the viewpoint of ensuring a smooth surface, it is preferably about 5 ⁇ m to 25 ⁇ m.
- a primer layer may be provided between the undercoat layer and the outer member or inner member in order to increase the adhesion between the undercoat layer and the outer member or inner member.
- topcoat layer A topcoat layer may be provided on the silver particle layer for the purpose of protecting the silver particle layer.
- the topcoat layer is a layer provided on the outermost surface of the decorative article, and the topcoat layer facilitates protection of the silver particle layer.
- the topcoat layer preferably has transparency that does not hide the silver particle layer, and may be colorless clear (colorless transparent) or colored clear (colored transparent).
- thermosetting resin examples include fluorine resin paints, polyester resin paints, epoxy resin paints, melamine resin paints, silicone resin paints, acrylic silicone resin paints, acrylic urethane resin paints, and acrylic silicone resin paints or acrylic urethane resin paints. is preferably used.
- Acrylic silicone resin coatings are excellent in adhesion to outer members or inner members, gloss retention, color retention, chemical resistance, oil resistance and water resistance.
- the acrylic urethane resin coating has a soft coating film, excellent adhesion, durability, weather resistance and chemical resistance. These resin paints may be used singly or in combination of two or more.
- the thickness of the top coat layer is not particularly limited, and is preferably about 20 ⁇ m to 40 ⁇ m. When the thickness of the topcoat layer is 20 ⁇ m or more, the silver particle layer tends to be sufficiently protected.
- the laminated structure of the present disclosure may include a configuration other than the outer member, the inner member, and the metal layer, and may include, for example, another member on at least one of the outer side of the outer member and the inner side of the inner member. .
- FIG. 4 A method for manufacturing the laminated structure described above will be described with reference to FIGS. 4 to 6.
- FIG. The laminated structure described above includes a step of preparing an outer member 31 having a concave portion 31A (FIG. 4), a step of preparing an inner member 32 having a convex portion 32A (FIG. 4), and a concave portion of the outer member 31.
- a laminated structure manufacturing method including a step of forming the portion 34 (FIG. 6).
- arrows indicate lasers, which are irradiated in the direction of the arrows.
- a metal layer may be formed on the surface of the outer member having the concave portion or the surface of the inner member having the convex portion.
- FIG. 4 an outer member with a metal layer is shown.
- the method for manufacturing a laminated structure of the present disclosure may include a step of forming a metal layer on the surface of at least one of the outer member and the inner member.
- the outer member and the inner member may be commercially available ones, or may be produced by a conventionally known method.
- the outer member and the inner member can be manufactured by injection molding a composition containing the above-described resin material and the like.
- the convex portion of the inner member should have a size that allows it to be inserted into the concave portion of the outer member.
- the width l2 of the convex portion to the width l1 of the concave portion shown in FIG. 4 (l2/l1) is preferably 0.9 or less, more preferably 0.7 or less.
- l is preferably 0.7 mm to 2.0 mm, more preferably 1.0 mm to 1.5 mm.
- l2 is preferably 0.5 mm to 1.8 mm, more preferably 0.8 mm to 1.2 mm.
- a method for manufacturing a laminated structure includes a step of inserting a convex portion into a concave portion.
- a method for manufacturing a laminated structure includes a step of heat-melting a convex portion of an inner member and fitting it to a concave portion of an outer member to form a fitting portion. By heating and melting the convex portion, the convex portion is deformed into a shape to be fitted with the concave portion, thereby forming the fitting portion.
- a method for heating and melting the convex portion is not particularly limited, but laser irradiation is preferable. By heating and melting the convex portion by laser irradiation, it is possible to control the heating area and tend to reduce damage to the inner member around the heated and melted convex portion.
- the outer member has a laser transmittance of 90% or more and the inner member has a laser transmittance of 30% or less, it is preferable to irradiate the laser from the surface on the outer member side.
- a method for manufacturing a laminated structure can include a step of forming a metal layer on the surface of at least one of the outer member and the inner member.
- a metal layer may be formed on one surface of the prepared outer member and inner member.
- the metal layer may be a metal particle layer or a silver particle layer as described above.
- the silver particle layer may be formed by a silver mirror reaction.
- the silver particles contained in the silver particle layer may include silver particles precipitated by a silver mirror reaction (precipitated silver particles).
- a method for manufacturing a laminated structure can include a step of forming an undercoat layer.
- the method of forming the undercoat layer is not particularly limited, and the undercoat layer can be formed by applying the above-described paint or the like to the surface of the outer member or the like and drying it.
- a method for manufacturing a laminated structure can include a step of forming a topcoat layer.
- the method of forming the topcoat layer is not particularly limited, and the topcoat layer can be formed by applying the above-described paint or the like to the surface of the metal layer and drying.
- the object detection structure of the present disclosure includes the laminated structure of the present disclosure described above and a millimeter wave radar that irradiates millimeter waves toward the laminated structure. Since the laminated structure of the present disclosure can reduce transmission attenuation of millimeter waves, the object detection structure of the present disclosure is excellent in millimeter wave radar transmission/reception performance.
- laminated structure of the present disclosure may be combined with a radar that transmits and receives radio waves other than millimeter waves.
- Example 1 (Preparation of outer material) As shown in FIG. 7, a polycarbonate (PC) base material (relative permittivity at 77 GHz: 2.8, dielectric loss tangent: 0.008) having an elliptical shape of 119 mm in length and 165 mm in width and a thickness of 4.2 mm in the general part was used as an outer layer. prepared as components. It should be noted that the general part refers to the part indicated by symbol H1 in FIG. The outer member used in Example 1 has a portion thinner than the general portion, and by forming a metal layer on the portion, when viewed from the side opposite to the metal layer forming surface, the portion appears to have floated. As shown in FIG.
- the outer member 41 had a concave portion 41A along its outer peripheral edge on one surface, and the width L1 of the concave portion was 1.2 mm. Further, when the laser transmittance of the outer member at a wavelength of 1070 nm was measured, it was 92%.
- a polycarbonate (PC) base material (relative permittivity at 77 GHz: 2.8, dielectric loss tangent: 0.008) having an elliptical shape of 119 mm in length and 165 mm in width and a thickness of 2.5 mm in the general part is used as an inner layer.
- the general portion refers to the portion indicated by symbol H2 in FIG. 8, and faces the general portion of the outer.
- the inner member used in Example 1 has a portion thicker than the general portion.
- the inner member 43 had a convex portion 43A along its outer peripheral edge on one surface, and the width L2 of the concave portion was 0.8 mm. Further, when the laser transmittance of the inner member at a wavelength of 1070 nm was measured, it was 0%.
- MSPS-Ag (trade name) and MSPS-Do (manufactured by Mitsubishi Paper Mills, Ltd.) were sprayed inwardly from the position where the concave portion of the outer member, which forms the fitting portion with the inner member, was provided using a two-head spray gun. (trade name)) to form a silver particle layer 42 by a silver mirror reaction (see FIG. 9).
- compressed air air blow
- the layer was dried in a drying oven set at 45°C for 30 minutes.
- Step of inserting convex portion into concave portion As described above, the inner member and the outer member having the undercoat layer and the metal layer formed on the surface having the concave portions were opposed to each other, and the convex portions of the inner member were inserted into the concave portions of the outer member.
- Step of forming the mating portion Using Panasonic's VL-W1A00, a laser with a wavelength of 1070 nm is irradiated from the surface of the outer member to the convex portion inserted into the concave portion, and the convex portion is pressed while pressing the outer member toward the inner member side. It was heated and melted to fit into the concave portion to form a fitting portion, thereby obtaining a laminate structure.
- the mating portion is formed along the shape of the laminated structure (that is, elliptical shape) to form a specific region.
- the distance d between the inner peripheral edge of the fitting portion and the outer peripheral edge of the laminated structure is 1.2 mm.
- a laminate structure was manufactured by insert molding. Specifically, it is as follows. An outer member having no concave portion and a metal layer was prepared in the same manner as in Example 1. A laminate structure was obtained by placing the outer member in a mold, injecting heat-melted polycarbonate into the mold, and molding the inner member on the outer member. In the laminated structure, the inner member and the outer member were bonded over the entire surface, and the appearance of the bonded portion was good.
- Example 1 As shown in Table 1, the laminate structure of Example 1 was found to be superior in appearance to the laminate structure of Comparative Example 1.
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Abstract
Description
自動衝突回避システムは、車載カメラの画像データ及びミリ波レーダーによる対象物との相対距離情報を用いて自動的にブレーキをかけるものである。
しかしながら、インサート成型における高温、高圧等により金属層がダメージを受け、積層構造体の外観の悪化が問題となり、製品の意匠性を損なうおそれがある。
また、金属層へのダメージを考慮し、インナー部材又はアウター部材に保護フィルム等を設けること等が行われているが、製造コスト及び生産性等に問題がある。
<1> 凹状部を有するアウター部材と、金属層と、上記凹状部と篏合し、篏合部を形成する凸状部を有するインナー部材と、をこの順に備える、積層構造体。
<2> 上記篏合部により囲まれる領域を有する、上記<1>に記載の積層構造体。
<3> 上記勘合部が、積層構造体外周端部から3mm以内に設けられる、<1>又は<2>に記載の積層構造体
<4> 上記金属層が、銀粒子層を備える、上記<1>~<3>のいずれか1つに記載の積層構造体。
<5> 上記金属層が、金属粒子が島状に点在する海島構造を有する、上記<1>~<4>のいずれか1つに記載の積層構造体。
<6> 移動体の外装部材として用いられる上記<1>~<5>のいずれか1つに記載の積層構造体。
<7> 上記<1>~<6>のいずれか1つに記載の積層構造体と、上記積層構造体に向けてミリ波を照射するミリ波レーダーと、を備える対象物検知構造。
本開示中に段階的に記載されている数値範囲において、一つの数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本開示中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
本開示において、各成分には、該当する物質が複数種含まれていてもよい。
本開示において、各成分に該当する粒子には、複数種の粒子が含まれていてもよい。
本開示において「層」又は「膜」との語には、当該層又は膜が存在する領域を観察したときに、当該領域の全体に形成されている場合に加え、当該領域の一部にのみ形成されている場合も含まれる。
本開示において、各層の厚さは、ミクロトーム等を用いて測定対象から試験片を作製し、電子顕微鏡により任意の5箇所の厚さを測定して得られた算術平均値をいう。
本開示において、「(メタ)アクリル」は、アクリル及びメタクリルの両方を包含する概念で用いられる語である。
本開示において「工程」との語には、他の工程から独立した工程に加え、他の工程と明確に区別できない場合であってもその工程の目的が達成されれば、当該工程も含まれる。
本開示の積層構造体は、凹状部を有するアウター部材と、金属層と、上記凹状部と篏合し、篏合部を形成する凸状部を有するインナー部材と、をこの順に備える。
なお、前述の差の下限は特に限定されない。
本開示において、比誘電率は、いずれも77GHzでの値を意味する。
図2に示すように、積層構造体10は、凹状部1Aを有するアウター部材1と、金属層2と、上記凹状部1Aと篏合し、篏合部を形成する凸状部3Aを有するインナー部材3と、をこの順に備える。また、図2にて矢印で示すように積層構造体10をミリ波が透過する。
図1において、凹状部1A及び凸状部3Aが篏合する篏合部4は点線で示す。
また、図2において、篏合部を形成する凸状部及び凹状部の幅を符号lで示し、篏合部の高さを符号hで示す。
積層構造体が、特定領域を有することにより、アウター部材及びインナー部材の間の気密性が向上し、特定領域内の金属層等の経時的な劣化を抑制することができる傾向にある。
積層構造体10は、図1に示す形態に限定されるものではなく、図4に示すように、特定領域を有さず、篏合部24が、長さ方向又は幅方向に略平行に配置されていてもよい。なお、図4において、積層構造体は符号30で、アウター部材は符号21で、篏合部は符号24で示す。
本開示において、積層構造体外周端部とは、アウター部材及びアウター部材のいずれか面積の小さい部材の端部を意味する。
図3において、篏合部の内周端部と積層構造体外周端部との距離をdで示す。
また、気密性及び篏合部の強度の観点から、篏合部の高さhは、0.1mm~1.0mmであることが好ましく、0.3mm~0.8mmであることがより好ましい。
本開示の積層構造体は、凹状部を有するアウター部材を備える。
凹状部の形状は、特に限定されるものではなく、図1に示すように、断面が、略長方形状であってもよい。
(メタ)アクリル樹脂としては、ポリメタクリル酸メチル(PMMA)樹脂を含むことが好ましい。
ポリプロピレンは、樹脂材料の中でも比重が軽く、加工しやすく、引張強度、衝撃強度及び圧縮強度が高く、耐候性及び耐熱性にも優れている。
ABS樹脂は、プラスチック素材の中でも比較的表面処理を施しやすく、よって成形後に塗装等を施しやすい樹脂であり、耐薬品性及び剛性に優れ、耐衝撃性、耐熱性及び耐寒性にも長けている。
PCは、プラスチック素材の中でも耐衝撃性が高く、耐候性及び耐熱性にも優れ、透明性にも長けている。また、ポリカーボネートは、加工もしやすく、プラスチック素材の中でも比較的軽く、丈夫な素材である。
レーザーとしては、例えば、800nm~1100nmの波長を有するレーザーを使用することができる。
本開示の積層構造体は、アウター部材が有する凹状部と篏合する凸状部を有し、アウター部材と対向するインナー部材を備える。篏合部における凸状部の形状は、特に限定されるものではないが、凹状部の形状に沿った形状を有していることが好ましい。
また、好ましい樹脂材料については、アウター部材と同様であるため、ここでは記載を省略する。
本開示の積層構造体は、アウター部材とインナー部材との間に金属層を備える。
また、金属粒子層は、金属粒子が島状に点在する海島構造を有するものであってもよい。
積層構造体における銀粒子層の厚さ方向の断面について、30万倍の倍率で透過型電子顕微鏡写真を撮影する。得られた電子顕微鏡写真に対して、銀粒子層の厚さ方向の中央を通る中央線を決定する。次いで、中央線と銀粒子とが重複する部分の長さを求める。中央線と銀粒子とが重複する部分の長さを中央線全体の長さで除した値の百分率を、銀粒子層に占める銀粒子の割合と定義する。
銀粒子層の表面抵抗率の上限は、特に限定されない。
銀粒子層の表面抵抗率は、JIS K6911:2006に準じて測定された値をいう。
アウター部材又はインナー部材と銀粒子層との密着性を向上させる観点、及び、アウター部材又はインナー部材に平滑面を形成する観点から、アウター部材又はインナー部材と銀粒子層との間に、アンダーコート層が設けられてもよい。
銀粒子層の保護を目的として、銀粒子層上にトップコート層が設けられてもよい。
トップコート層は、装飾品の最外面に設けられる層であり、トップコート層によって銀粒子層が保護されやすくなる。
トップコート層としては、銀粒子層を隠蔽しない透明性を有することが好ましく、無色クリア(無色透明)であっても、着色されたカラークリア(有色透明)であってもよい。
上記した積層構造体の製造方法について、図4~図6を参照しながら説明する。
上記した積層構造体は、凹状部31Aを有するアウター部材31を準備する工程と(図4)、凸状部32Aを有するインナー部材32を準備する工程と(図4)、アウター部材31の凹状部31Aへインナー部材32の凸状部32Aを挿入する工程と(図5)、インナー部材32の凸状部32Aをレーザー等により加熱溶融し、アウター部材31の凹状部31Aと篏合させ、篏合部34を形成する工程と(図6)、を含む積層構造体の製造方法により製造することができる。
なお、図6において、矢印は、レーザーを示し、矢印の方向へ向けて照射される。
なお、上記積層構造体の製造方法において、アウター部材の凹状部を有する面又はインナー部材の凸状部を有する面には、金属層が形成されていてもよい。図4においては、金属層を備えるアウター部材を示す。
また、本開示の積層構造体の製造方法は、アウター部材及びインナー部材の少なくとも一方の表面に金属層を形成する工程を含んでいてもよい。
アウター部材及びインナー部材は、市販されるものを使用してもよく、従来公知の方法により製造してもよい。
例えば、上記した樹脂材料等を含む組成物を射出成型することにより、アウター部材及びインナー部材を製造することができる。
図4に示す凹状部の幅l1に対する凸状部の幅l2(l2/l1)は、0.9以下であることが好ましく、0.7以下であることがより好ましい。
気密性及び篏合部の強度の観点から、lは、0.7mm~2.0mmであることが好ましく、1.0mm~1.5mmであることがより好ましい。
気密性及び篏合部の強度の観点から、l2は、0.5mm~1.8mmであることが好ましく、0.8mm~1.2mmであることがより好ましい。
積層構造体の製造方法は、凹状部へ凸状部を挿入する工程を含む。
積層構造体の製造方法は、インナー部材の凸状部を加熱溶融し、アウター部材の凹状部と篏合させ、篏合部を形成する工程を含む。
凸状部の加熱溶融により、凸状部が凹状部と篏合する形状に変形し、篏合部が形成される。
アウター部材のレーザー透過率が90%以上であり、インナー部材のレーザー透過率が30%以下である場合、アウター部材側の表面からレーザー照射を行うことが好ましい。
積層構造体の製造方法は、アウター部材及びインナー部材の少なくとも一方の表面に金属層を形成する工程を含むことができる。
また、上記したアウター部材の準備工程及びインナー部材の準備工程において、準備されるアウター部材及びインナー部材の一方の表面に金属層が形成されていてもよい。
金属層は、上記したように金属粒子層であってもよく、銀粒子層であってもよい。
さらに、銀粒子層は、銀粒子が島状に点在する海島構造を呈していてもよい。
銀鏡反応による銀粒子層の形成は、水溶性銀塩水溶液並びに還元剤及び強アルカリ成分を含む還元剤水溶液の2液を、アウター部材の表面上、インナー部材の表面上、又は後述するアンダーコート層表面上(以下、これらの表面を、合わせて「銀鏡反応処理面」と称する場合がある。)で混合されるように塗布する。これにより酸化還元反応が生じて銀粒子が生じ、銀粒子層が形成される。
積層構造体の製造方法は、アンダーコート層を形成する工程を含むことができる。アンダーコート層の形成方法は、特に限定されるものではなく、上記した塗料等をアウター部材等の表面に塗布し、乾燥することにより形成することができる。
積層構造体の製造方法は、トップコート層を形成する工程を含むことができる。トップコート層の形成方法は、特に限定されるものではなく、上記した塗料等を金属層の表面に塗布し、乾燥することにより形成することができる。
本開示の対象物検知構造は、前述の本開示の積層構造体と、積層構造体に向けてミリ波を照射するミリ波レーダーと、を備える。本開示の積層構造体は、ミリ波の透過減衰量を低減可能であるため、本開示の対象物検知構造は、ミリ波レーダーの送受信性能に優れる。
(アウター部材の準備)
図7に示す、縦119mm、横165mmの楕円状で、一般部の厚さが4.2mmのポリカーボネート(PC)基材(77GHzでの比誘電率2.8、誘電正接0.008)をアウター部材として準備した。
なお、一般部とは、図7における符号H1で示される部位を指す。
実施例1で使用するアウター部材は、一般部よりも板厚が薄い部位を有し、上記部位に金属層を形成することにより、金属層形成面とは反対の面から目視したとき、上記部位が浮き上がったように見える。
上記アウター部材41は、図7に示すように、一方の面に、凹状部41Aをその外周端部に沿って有しており、凹状部の幅L1は、1.2mmであった。
また、アウター部材の波長1070nmのレーザー透過率を測定したところ、92%であった。
図8に示す、縦119mm、横165mmの楕円状で、一般部の厚さが2.5mmのポリカーボネート(PC)基材(77GHzでの比誘電率2.8、誘電正接0.008)をインナー部材として準備した。
なお、一般部とは、図8における符号H2で示される部位を指し、アウターの一般部と面対になる。
実施例1で使用するインナー部材は、一般部よりも板厚が厚い部位を有する。
上記インナー部材43は、図8に示すように、一方の面に、凸状部43Aをその外周端部に沿って有しており、凹状部の幅L2は、0.8mmであった。
また、インナー部材の波長1070nmのレーザー透過率を測定したところ、0%であった。
インナー部材と篏合部を形成する、アウター部材の凹状部が設けられた位置より内側へ、2頭スプレーガンを用いて、三菱製紙株式会社製のMSPS-Ag(商品名)とMSPS-Do(商品名)の2液を塗布し、銀鏡反応による銀粒子層42を形成した(図9参照)。
次いで、銀粒子層表面の水分を除去するため、圧縮空気(エアブロー)を吹き付けた後、45℃に設定した乾燥炉内で30分間乾燥した。
上記のように、凹状部を有する面に、アンダーコート層及び金属層を形成したアウター部材と、インナー部材とを、向かい合わせ、アウター部材の凹状部へインナー部材の凸状部を挿入した。
パナソニック社製のVL-W1A00を用いて、アウター部材の表面から、波長1070nmのレーザーを、凹状部へ挿入される凸状部へ照射し、アウター部材をインナー部材側に加圧しながら凸状部を加熱溶融し、凹状部と篏合させ、篏合部を形成し、積層構造体を得た。
積層構造体において、篏合部は、積層構造体の形状(すわなち、楕円形状)に沿って形成され、特定領域を形成する。
また、篏合部の内周端部と、積層構造体外周端部との距離dは1.2mmである。
篏合部の外観を目視により観察したところ、レーザー照射によるダメージは観察されず、良好な外観を有していた。
インサート成型により積層構造体を製造した。具体的には、以下の通りである。
実施例1と同様にして、凹状部を有さず、金属層を備えるアウター部材を準備した。
上記アウター部材を金型内に配置し、加熱溶融したポリカーボネートを金型内に射出し、アウター部材上にインナー部材を成型することにより、積層構造体を得た。
積層構造体は、インナー部材とアウター部材とが全面において接合しており、接合箇所の外観は良好であった。
上記実施例及び比較例において積層構造体を製造し、これを目視により観察し、下記評価基準に基づいて、評価した。
結果を表1に示す。
(評価結果)
A:積層構造体が高い光沢感を有しており、優れた外観を有することが確認された。
B:積層構造体が光沢感に劣り、その外観には改良の余地があった。
Claims (7)
- 凹状部を有するアウター部材と、金属層と、前記凹状部と篏合し、篏合部を形成する凸状部を有するインナー部材と、をこの順に備える、積層構造体。
- 前記篏合部により囲まれる領域を有する、請求項1に記載の積層構造体。
- 前記勘合部が、積層構造体外周端部から3mm以内に設けられる、請求項1又は請求項2に記載の積層構造体。
- 前記金属層が、銀粒子層を備える、請求項1~請求項3のいずれか一項に記載の積層構造体。
- 前記金属層が、金属粒子が島状に点在する海島構造を有する、請求項1~請求項4のいずれか一項に記載の積層構造体。
- 移動体の外装部材として用いられる請求項1~請求項5のいずれか一項に記載の積層構造体。
- 請求項1~請求項6のいずれか一項に記載の積層構造体と、
前記積層構造体に向けてミリ波を照射するミリ波レーダーと、
を備える対象物検知構造。
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