阅读说明：本技术 用于以多组分方法制造层状体的方法 (Method for producing a layered body in a multi-component method ) 是由 J·霍尔兹莱特纳 M·施瓦茨 于 2021-05-25 设计创作，主要内容包括：本发明涉及一种用于以多组分方法制造层状体(10)的方法,所述方法包括如下步骤：在第一制造步骤中,由透明的塑料、尤其是由聚碳酸酯制造基底(11),以及在第二制造步骤中,将基底(11)以透明的树脂层(17)、尤其是由聚氨酯制成的透明的树脂层进行覆层。(The invention relates to a method for producing a layered body (10) in a multi-component method, comprising the following steps: in a first production step, the substrate (11) is produced from a transparent plastic, in particular from polycarbonate, and in a second production step, the substrate (11) is coated with a transparent resin layer (17), in particular a transparent resin layer made of polyurethane.)

1. A method for manufacturing a laminar body (10) in a multi-component method, the method comprising the steps of:

in a first production step, a substrate (11) is produced from a transparent plastic, in particular from polycarbonate; and

in a second production step, the substrate (11) is coated with a transparent resin layer (17), in particular made of polyurethane.

2. Method according to claim 1, characterized in that after the production of the substrate (11), the substrate (11) is left in the production tool and the substrate (11) is coated during the positioning of the substrate (11) in the production tool.

3. The method according to claim 1 or 2, characterized in that a transparent heating film (16) is integrated between the substrate (11) and the resin layer (17).

4. A method according to claim 3, characterized in that a heating film (16) is applied onto the surface of the substrate (11) before coating the substrate (11) and subsequently covered with the resin layer (17) over the entire surface during flooding, wherein the heating film (16) is completely embedded between the resin layer (17) and the substrate (11) after coating.

5. Method according to any one of claims 1 to 4, characterized in that the lacquer layer (12) is applied directly on the surface of the substrate (11) facing away from the resin layer (17).

6. Method according to claim 5, characterized in that the lacquer layer (12) is first applied over the entire surface of the substrate (11) facing away from the resin layer (17) and is subsequently removed at least in sections by means of laser ablation or by means of a mechanical machining, in particular a milling machining.

7. Method according to claim 5, characterized in that before the application of the lacquer layer (12), a mask is applied at least locally on the surface of the substrate (11) facing away from the resin layer (17), wherein the lacquer layer (12) is applied to the mask in the masked areas and directly to the surface of the substrate (11) in the unmasked areas.

8. Method according to claim 5, characterized in that the lacquer layer (12) is applied by means of a printing method at least on the side of the substrate (11) facing away from the resin layer (17), wherein the lacquer layer (12) is applied only locally to the surface of the substrate (11) and in this case a region with the lacquer layer (12) and a region without the lacquer layer (12) are produced on this surface.

9. Method according to one of the preceding claims 5, 6, 7 or 8, characterized in that after the production of the lacquer layer (12), a transparent adhesion promoter layer (13), in particular a transparent adhesion promoter layer with a layer thickness of 5 μm to 50 μm, is applied to the lacquer layer (12).

10. Method according to claim 9, characterized in that a decorative layer (14) made of a semiconductor is applied onto the transparent adhesion promoter layer (13) by means of physical vapor deposition, in particular by means of sputtering.

11. Method according to claim 10, characterized in that an opaque surface coating (15) is applied to the decorative layer (14) by means of a spraying method.

12. A method according to any one of the preceding claims, characterized in that the end side surface of the substrate (11) provided with one or more layers, including the substrate (11), is sealed with a resin (18).

13. A laminate (10) comprises a substrate (11) made of a transparent plastic, in particular polycarbonate, and a coating made of a transparent resin layer (17), in particular polyurethane, on the substrate (11).

14. Laminar body (10) according to claim 13, characterized in that a transparent heating film (16) is integrated between the substrate (11) and the resin layer (17).

15. Laminar body (10) according to claim 13 or 14, characterized in that the heating film (16) is covered on the whole surface by a resin layer (17), wherein the heating film (16) is completely embedded between the resin layer (17) and the substrate (11).

16. Laminar body (10) according to one of claims 13 to 15, characterized in that a lacquer layer (12) is provided directly on the surface of the substrate (11) facing away from the resin layer (17).

17. Laminar body (10) according to claim 16, characterized in that a transparent adhesion promoter layer (13), in particular a transparent adhesion promoter layer with a layer thickness of 5 μm to 50 μm, is provided on the lacquer layer (12).

18. Laminar body (10) according to claim 17, characterized in that a decorative layer (14) made of a semiconductor is applied onto the transparent adhesion promoter layer (13) by means of physical vapour deposition, in particular by means of sputtering.

19. Laminar body (10) according to claim 18, characterized in that an opaque surface coating (15) is applied on the decorative layer (14) by means of a spraying method.

20. Laminar body (10) according to claim 19, characterized in that the end side surfaces of the substrate (11) provided with one or more layers, including the substrate (11), are sealed with a resin (18).

Technical Field

The invention relates to a method for manufacturing a layered body according to the preamble of claim 1.

Background

In the modern vehicle manufacturing industry, there have been efforts for some time to realize vehicles that travel automatically. Radar-based systems are used to detect objects located in a vehicle environment. Current radomes (coverings in front of the front radar of the vehicle) comprise a multi-shell structure, which usually comprises at least two injection-molded parts that must be joined to each other. The two individual components are then joined (for example by gluing) to form a composite structure which in the final state must be designed to be sealed against the ingress of media. The heating device is mounted in the component on the rear side in the non-visible region and then the front side of the component must be heated through the two plastic shells and the air gap, which leads to increased energy consumption and/or poor heating performance.

The current design of radomes with a double-shell structure and an air gap between the two shell parts is dependent on temperature, humidity, etc. in the radar function for the identification of objects.

EP2640609B1 shows a radome of the same type for a vehicle.

Disclosure of Invention

Starting from this prior art, the object of the present invention is to provide a method for producing a layered body which is particularly suitable for use as a radome.

In order to solve this object, the invention proposes a method for producing a layered body in a multi-component method, comprising the following steps:

in a first production step, a substrate is produced from a transparent plastic, in particular from polycarbonate; and

in a second production step, the substrate is coated with a transparent resin layer, in particular made of polyurethane. Here, the transparent resin layer may have a self-repairing property. Preferably, the resin layer forms the outer side of the layered body, and the self-healing layer in the sense of the present application is a resin system which has a self-healing effect by heat action or time in the case of scratches or spots, by which the scratches can be closed again or the spots can be eliminated. This effect is produced, for example, by physical bonds (e.g. hydrogen bonds) in the resin layer, which break and then recover again in the case of damage (e.g. scratches) as long as no cutting damage occurs. This provides the advantage of an increased scratch resistance, by means of which the radar system can continue to maintain unlimited function even in the event of a stone impact or similar load. The wall thickness of the substrate connected to the transparent resin layer can be selected here such that it is several times the wavelength in the material for the radar-relevant frequency range. Therefore, attenuation minimization can be achieved for a radar wave of a specific frequency. The resin layer may have radar penetration similar or identical to that of the substrate in order to minimize reflection in the boundary layer. The resin layer may have a layer thickness in the range of 0.5mm to 2.0 mm. Preferably, the layer thickness of the resin layer is in the range of 0.5mm to 1.0mm in order to achieve shorter cycle times and reduce possible surface waviness. The multilayer component produced according to the method can provide increased design freedom, more favorable tolerance conditions and improved radar and heating behavior when used as a radome, compared to a two-shell design.

After the substrate is produced, the substrate may remain in the manufacturing mold, wherein the substrate is coated during the time the substrate is in the manufacturing mold. This eliminates an additional operating step, which has a positive effect on the quality, in particular with regard to tolerances, contamination and damage.

A transparent heating film may be integrated between the substrate and the resin layer. Preferably, the heating film may be made of the same base material as the base produced in the first manufacturing step. The heating film has a predetermined conductor pattern, wherein the conductors are applied to the film surface and are at least partially immersed in the film, for example by means of a vibration method. If these wires with a defined resistance are energized, the heat required for heating the radome is generated. In this case, the wires are arranged such that the component surface is heated over the entire surface and uniformly.

The heating film can be applied to the surface of the substrate before coating the substrate and then covered over the entire surface with the resin layer in a flood process (Flutprozess), wherein after coating the heating film is completely embedded between the resin layer and the substrate. Here, the resin layer forms the front side of the layered member. This ensures an optimized heating performance of the front side of the component and avoids the development of a heating film on the visible side of the component.

Furthermore, the lacquer layer can be applied directly to the surface of the substrate facing away from the resin layer. The lacquer layer may have a defined radar transparency, which is preferably equal to the radar transparency of the substrate and/or the resin layer, and the lacquer layer is applied in a layer thickness of 5 μm to 50 μm.

According to a first variant of the method, the lacquer layer can first be applied over the entire surface of the substrate facing away from the resin layer, and the lacquer layer can then be removed at least in places by means of laser ablation. The removal of the lacquer layer can take place both in sections of the finished component with an abrupt change in wall thickness and in sections with a constant wall thickness. The former is especially the case in areas where three-dimensional patterns should be created.

According to a second variant of the method, before the application of the lacquer layer, a mask can be applied locally on the surface of the substrate facing away from the resin layer, wherein the lacquer layer is applied to the mask in the masked regions and directly to the surface of the substrate in the unmasked regions. The masking zone is in particular arranged in an area in which a two-dimensional or three-dimensional pattern should be produced.

According to a third variant of the method, the lacquer layer can be applied at least on the side of the substrate facing away from the resin layer by means of a printing method, in particular by means of ink jet, digital printing, screen printing, wherein the lacquer layer is applied only locally to the surface of the substrate and in this case regions with lacquer layer and regions without lacquer layer are produced on this surface. Thereby selectively coating the backside of the substrate and creating the desired pattern directly upon application of the first color. Selective removal of the layers by means of a laser is thus no longer necessary. The areas without lacquer layer are in particular arranged at locations where a two-dimensional or three-dimensional pattern should be formed.

According to a fourth variant, in order to produce the first color layer, a lacquer layer can be produced by applying a heat-pressed film. The layer thickness and the material selection of the thermoprinting film need to be selected optimally for the radar performance of the entire component.

According to a fifth variant, in order to produce the first color layer, a printed or coated film can be directly back-injection-molded (hingerspriven) onto the component surface opposite the additional resin layer during the production of the substrate. Here, prior to producing the substrate, the printed or coated color layer is introduced into a production mold where the substrate is produced. The printed or coated film is then back injection molded with the base material. Two-dimensional or three-dimensional patterns can also be produced.

Furthermore, after the production of the lacquer layer, a transparent adhesion promoter layer, in particular a transparent adhesion promoter layer having a layer thickness of 5 μm to 50 μm, can be applied to the lacquer layer. The adhesion promoter layer serves to improve the adhesion of the subsequent decorative layer and can be embodied with or without matting agents in order to influence the visual effect, such as a high gloss or matte, of the subsequent decorative layer. The composition and layer thickness of the transparent adhesion promoter layer are also optimized with respect to radar transparency.

A decorative layer made of a semiconductor or a combination of a semiconductor and a conductor can be applied to the transparent adhesion promoter layer by means of physical vapor deposition, in particular by means of sputtering. The coating can also be carried out by means of chemical vapor deposition. The decorative layer ensures a metallic look and feel of the second color and is at the same time radar-transparent. For cost-effective formation of the target color, the layer thickness of the decorative layer is between 10nm and 300nm, preferably between 15nm and 80 nm. The layer is made of silicon, germanium, boron, selenium, tellurium, arsenic, antimony or a mixture of these elements. Furthermore, metals, in particular chromium, can be added in small amounts to the sputtered semiconductor material in order to form the desired color of the decorative layer. In order to ensure radar transparency, the ratio should not exceed 10% by volume.

An opaque surface coating can be applied to the decorative layer by means of a spray coating process. The surface coating may have a layer thickness of 5 μm to 150 μm and be radar-transparent, so that its layer thickness is also optimized for radar performance. This surface coating is the final layer and at the same time serves for the backside sealing of the component. The surface coating may protect other layers from the environment as well as prevent unwanted illumination through or across the component from the backside. If such transmission or shine-through is desired, the surface coating should correspondingly be designed to be transparent.

Further, the end side surface of the substrate provided with one or more layers may be sealed with a resin.

Instead of a coating combining a layer of adhesion promoter with a decorative sputtered layer and a final surface coating, a further decorative paint layer or printing in a second color can be applied to produce the second color. In this case, it should be ensured that the second color is radar-transparent and adheres sufficiently to the layer lying therebelow.

By a suitable choice of the second color layer, the adhesion promoter layer and the final surface coating can also be dispensed with if necessary.

In a further aspect, the invention relates to a laminate comprising a substrate made of a transparent plastic, in particular polycarbonate, and a coating made of a transparent resin layer, in particular polyurethane, on the substrate.

A transparent heating film may be integrated between the substrate and the resin layer.

Further, the heating film may be entirely covered with the resin layer, wherein the heating film is entirely buried between the resin layer and the substrate.

Furthermore, a lacquer layer can be provided directly on the surface of the substrate facing away from the resin layer.

A transparent adhesion promoter layer, in particular a transparent adhesion promoter layer having a layer thickness of 5 μm to 50 μm, can be provided on the lacquer layer.

A decorative layer made of a semiconductor can be applied to the transparent adhesion promoter layer by means of physical vapor deposition, in particular by means of sputtering.

An opaque surface coating can be applied to the decorative layer by means of a spray coating method.

The end side surface of the substrate provided with one or more layers including the substrate is sealed with resin.

The advantages of the present invention are summarized below. The advantages mentioned in connection with the method also apply to the lamina and vice versa.

By producing the layered body in a multicomponent method, a multi-layered component can be produced which serves as a front kidney or front grille with integrated radome function. By means of such a design, the component can ensure a significantly improved radar function, while at the same time optimizing the heating function. In addition, separate components are saved, a unique 3D effect is produced and a special appearance with a depth effect can be achieved. The pattern can be varied and personalized by selectively removing the first lacquer layer. With this method the radome can be integrated into the complete front grille/front kidney of the vehicle and thus present a seamless appearance. The reduction of seams on the vehicle exterior also improves the aerodynamic properties of the vehicle and also reduces fuel consumption. All layers are optimized with regard to layer thickness to achieve optimum radar penetration and to produce sufficient adhesion throughout the service life of the vehicle in the overall composite structure. The method of producing the substrate is selected such that no separation of the components of the membrane is visible, wherein the integrated membrane has a smaller dimension than the entire component. The finished blank (substrate, resin layer and heating means) has a constant wall thickness in the radar field of view. Outside the field of view of the radar, the wall thickness of the rear side of the plastic component can be modified by means of this design, so that a pattern with a 3D depth effect is produced, which is based on the design of the plastic technology and the resin layer on the outside without causing damage to the class a surface of the component. The wall thickness of the substrate may vary depending on the initial wall thickness, for example, at an initial wall thickness of 5.2mm, the wall thickness may be varied by up to 3.0 mm. The wall thickness of the resin layer on the front side of the component must be selected such that it is at least 0.5 mm. By means of such a wall thickness, on the one hand the shrinking effect can be masked and, on the other hand, the resin layer can be selected such that it has a self-healing effect in the event of scratches or specks by the action of heat or time.

Drawings

The invention will be explained in more detail below with reference to the description of the figures. The attached drawings are as follows:

figure 1 shows a cross-section through a laminar body according to the invention.

Detailed Description

Figure 1 shows a cross-sectional view of a laminar body 10 which is made in a multi-component process and which is used as a radome. The radome 10 may serve as an outer covering member of a vehicle and cover the radar sensor 20 disposed inside the vehicle. The radar sensor 20 disposed behind the radome 10 is not visible from the outside of the vehicle.

Radome 10 has a base 11. A resin layer 17 is applied to the surface of the substrate 11 facing away from the radar sensor 20. A heating film 16 is at least partially provided between the resin layer 17 and the substrate 11. The outer surface of the resin layer 17 and thus of the radome 10 can be tempered, in particular heated, by means of the heating film 16 in order to ablate deposits such as rain, ice or snow. Furthermore, the heating film can be controlled such that a temperature is induced in the resin layer 17 at which a self-repair process is triggered, by means of which damage, such as scratches or pores, in the surface of the resin layer are closed.

A lacquer layer 12 is applied to the rear side of the base 11, i.e. to the surface of the substrate 11 facing the radar sensor 20. The lacquer layer has through-holes or recesses 19, 19' arranged in a pattern. By means of the lacquer layer 12, a radome color which is visible from the outside can be produced. An adhesion promoter layer 13 is applied to the surface of the lacquer layer 12 facing away from the substrate 11. A decorative layer 14 is applied to this adhesion promoter layer, which decorative layer can be seen from the outside of the vehicle or from the outside of the radome 10 through the recesses 19, 19' in the lacquer layer 12. Thus, a two-color effect of the radome can be produced. A final layer of opaque surface coating is applied to the side of the decorative layer 14 facing the radar sensor 20. The layers and the end sides of the substrate may be sealed with a resin 18. Preferably, the resin 18 completely surrounds the radome 10 or the substrate 11 and all layers 12, 13, 14, 15 and 17 in the circumferential direction. To avoid scattering light, the resin 18 may preferably be made of a black material.

The working principle of the radome 10 is briefly explained below. The radar sensor 20 emits radar waves in the emission direction E. These radar waves penetrate the radome 10 from the backside, starting from the opaque surface coating 15 and up to the resin layer 17. After leaving the radome through the resin layer 17, the radar waves encounter an object 30 located in front of the radome or in front of the vehicle. The radar waves are reflected at the object 30 and penetrate the radome in the reflection direction R. The radar waves pass through the radome in the opposite direction, i.e. this time from the resin layer 17 to the surface coating 15. After leaving the radome 10 through the surface coating 15, the radar waves are again received by the radar sensor 20.