DE102018005597A1 - Process for producing a radar cover plate and radar cover plate - Google Patents

Abstract

The invention relates to a method for producing a radar cover plate (1), comprising a first front component half (3) with a front (5) and a rear (7) and a second rear component half (9) with a front (11) and a rear side (13), the first component half (3) being made of a light and radar translucent plastic and having a decorative element (15). The method is characterized in that the second component half (9) is produced by a method with the following steps, the front (11) of the second component half (9) being inseparable from the rear (7) of the first component half (3) during the process: a) arranging at least one X heating wire (21) on the rear (7) of the first component half (3) in such a way that the radar cover plate (1) obtained from the process can be heated, and / or Arranging at least one light guide (23) on the back (7) of the first component half (3) in such a way that the radar cover plate (1) obtained from the method can be illuminated, b) casting the at least one X- Heating wire (21) and / or at least one light guide (23) on the back (7) of the first component half (3) with a light and radar translucent casting compound (25) in such a way that the radar cover plate (1 ) has a uniform component thickness and there is no air gap (19) around the X heating wires (21) and / or light guides (23) arranged according to method step a).

Description

The invention relates to a method for producing a radar cover plate and a radar cover plate.

Usually, radar cover plates - sometimes also referred to as ART plates or radomes - are made from two parts, which have to be glued together and also contain a membrane, so that there is no air gap between the parts in the event of thermal expansion. The front half of the component is usually made of polycarbonate and has a decorative element, such as a 3D element or a manufacturer's emblem. A scratch-resistant coating is applied to the front of the front half of the component to protect it from scratches and, as a result, to impair interference-free transmission of radar waves. This coating must primarily protect the front half of the component against scratches but also against stone chips. The rear, second component half on the back of the first or front component half is necessary to compensate for differences in thickness in the front component half, which result from the display of decorative elements - 3D element or manufacturer emblem. However, a uniform component thickness is absolutely necessary for a radar cover plate, since otherwise the radar transparency will be impaired. In addition to a uniform component thickness, an air gap-free design of the component is also necessary. Otherwise there will also be problems with the radar transparency. If decorative elements are now to be illuminated, light conductors have to be integrated into the radar cover plate in a very complex manner, whereby care must be taken to ensure that there are no air gaps as a result.

From the German published application DE 10 2005 015 323 A1 a method for producing a radome for a distance warning radar is known, wherein a cover plate is made of a radar and visually transparent material. The back of the cover plate is provided, at least in some areas, with a layer which reflects electromagnetic radiation in the visible wavelength range and allows longer wavy radar waves to pass through almost unattenuated.

From the published application DE 102 48 915 A1 A radar sensor and a method for producing a radar sensor for a vehicle are known, in particular for arrangement on a body part of a vehicle, with an upwardly open, trough-shaped housing, with an antenna arranged on the inside of the housing, in the region of the housing base a high-frequency part coupled to the antenna and a low-frequency part connected to the high-frequency part, the interior of the housing being filled with a moisture-proof filling compound.

From the German publication DE 11 2015 006 455 T5 a system and a method for arranging a radar transceiver unit within a system is known. The system includes a radar transceiver that includes an antenna array to transmit and receive energy within a frequency range, and a fairing to cover the antenna array. The system also includes a structure disposed between the antenna array and the shroud, the structure comprising a first base on a side closest to the antenna array and a second base on a side closest to the shroud, the the first base is smaller than the second base and the structure has a shape such that a series of cross sections from the first base to the second base show a gradual increase in size.

The aforementioned problems arise with the publications mentioned.

The invention is therefore based on the object of providing a method for producing a radar cover plate and a radar cover plate, the disadvantages mentioned not occurring.

The object is achieved by creating the subject matter of the independent claims. Advantageous configurations result from the subclaims.

1. a) Anordnen von mindestens einem X-Heizdraht auf der Rückseite der ersten Bauteilhälfte in der Art, dass die aus dem Verfahren erhaltene Radarabdeckplatte beheizbar ist, und/oder Anordnen von mindestens einem Lichtleiter auf der Rückseite der ersten Bauteilhälfte in der Art, dass die aus dem Verfahren erhaltene Radarabdeckplatte beleuchtbar ist,
2. b) Vergießen des in Schritt a) angeordneten mindestens einen X-Heizdraht und/oder mindestens einen Lichtleiters auf der Rückseite der ersten Bauteilhälfte mit einer Licht- und Radar-transluzenten Vergussmasse in der Art, dass die aus dem Verfahren erhaltene Radarabdeckplatte eine gleichmäßige Bauteildicke aufweist und um den gemäß Verfahrensschritt a) angeordneten mindestens einen X-Heizdraht und/oder mindestens einen Lichtleiter kein Luftspalt besteht.

Durch das Vergießen gemäß Verfahrensschritt b) entsteht die zweite Bauteilhälfte beziehungsweise wird die zweite Bauteilhälfte erhalten. Auf diese Weise können kostengünstig beleuchtbare Radarabdeckplatten mit integrierten Heizsystemen hergestellt werden. Weiterhin wird hierdurch die Möglichkeit bereitgestellt, dass sehr große Bauteile - beispielsweise die gesamte Kühlerabdeckung - mit beleuchtbaren Zierelementen, die radar-transluzent beziehungsweise radar-transparent sind, möglich wird. Mit anderen Worten wird die Abdeckung von mehreren Radarsensoren (ortsunabhängig) mit einer einzigen Abdeckplatte möglich. Ferner kann durch den Einsatz von Vergussmaterialien mit einem relativ geringen E-Modul und entsprechend hoher Dehnfähigkeit auch eine Verformung der ersten Bauteilhälfte durch die Schwindung des Vergussmaterials fast vollständig vermieden werden. Dies trifft insbesondere dann zu, wenn die Vergussmasse nur partiell auf der ersten Bauteilhälfte aufgebracht wird. Aus diesem Grund ist bevorzugt vorgesehen, dass in Verfahrensschritt b) das Vergießen mit einer Vergussmasse nur partiell - das heißt, dass die Rückseite nicht vollständig in Bezug auf ihre Ausdehnung/Fläche mit einer Vergussmasse versehen wird - auf der Rückseite der ersten Bauteilhälfte durchgeführt wird.The object is achieved in particular by creating a method for producing a radar cover plate, comprising a first front component half with a front and a rear and a second rear component half with a front and a rear, the first component half comprising a light and Radar-translucent plastic is produced and has a, preferably seamlessly integrated, decorative element, which is preferably applied to a component half back. The method according to the invention is characterized in that the second component half is produced by a method with the following steps, the front side of the second component half being inseparably connected to the back of the first component half during the method:

1. a) arranging at least one X heating wire on the back of the first component half in such a way that the radar cover plate obtained from the method can be heated, and / or arranging at least one light guide on the back of the first component half in such a way that the the radar cover plate obtained by the method can be illuminated,
2. b) casting the at least one X heating wire and / or at least one light guide arranged in step a) on the back of the first component half with a light and radar translucent casting compound in such a way that the radar cover plate obtained from the method has a uniform component thickness and there is no air gap around the at least one X heating wire and / or at least one light guide arranged according to method step a).

By casting according to method step b), the second component half is created or the second component half is obtained. In this way, radar cover plates with integrated heating systems can be produced at low cost. Furthermore, this provides the possibility that very large components - for example the entire radiator cover - can be made with illuminable decorative elements that are radar-translucent or radar-transparent. In other words, multiple radar sensors (regardless of location) can be covered with a single cover plate. Furthermore, by using potting materials with a relatively low modulus of elasticity and correspondingly high elasticity, deformation of the first component half due to the shrinkage of the potting material can be almost completely avoided. This is particularly true if the casting compound is only partially applied to the first half of the component. For this reason, it is preferably provided that in method step b) the casting with a casting compound is carried out only partially - that is to say that the back is not completely provided with a casting compound with respect to its extent / area - on the back of the first component half.

In connection with the present invention, the term “light” is to be understood as meaning a light which is visible to Homo Sapiens and which in particular has a wavelength of 400 nm to 800 nm.

In connection with the present invention, the term “radar” should be understood to mean electromagnetic radiation which has a wavelength of 1 mm to 10 m or a frequency range of 30 MHz to 300 GHz.

In connection with the present invention, the terms “X heating wire”, “Y heating wire” and “Z heating wire” are understood to mean an electrical heating resistor. Furthermore, in the context of the present invention, the letters X, Y and Z should not imply any order or priority before the term heating wire, unless it is expressly mentioned. Furthermore, it can be provided according to the invention that in the radar cover plate obtained from the method according to the invention, or the front and rear component halves, there is no X and no Z heating wire, but only a Z heating wire. However, other combinations such as an X and Z heating wire without a Y heating wire are also possible.

In a particularly preferred embodiment, it is provided that the front of the first front component half has at least one Y heating wire. For this, it is particularly preferred for the first front component half to be produced by back-molding a film with, preferably a thin, at least one Y-heating wire with a plastic, in particular polycarbonate. This has the particular advantage that the heat resulting from the at least one Y heating wire can heat ice or snow particularly efficiently on the front side of the first front component half and thus cause it to melt.

In a further development of the invention it is provided that at least one Z-heating wire is arranged on the back of the first component half and the at least one Z-heating wire is introduced into the back of the first front component by means of heat, preferably by ultrasound. This has the particular advantage that the Z-heating wire can be inserted into the first front component half without air gaps.

Furthermore, it is particularly preferably provided that the at least one Z heating wire is arranged on the back of the first component half when the first component half is very thin, in particular a thickness of 1 to 15 mm, preferably 2 to 10 mm, particularly preferably 3 up to 8 mm, particularly preferably 4 to 6 mm, wherein a method according to the invention is then preferably carried out.

It is particularly preferably provided that the at least one X heating wire is cast according to method step a) in method step b) in such a way that the at least one X heating wire is located directly in or in the region of the front of the second rear component half.

According to a development of the invention, it is provided that a method step a0) is switched before method step a), which comprises positioning the first component half with the front side - geodetically - downwards. This has the particular advantage that casting according to method step b) can be carried out particularly easily and inexpensively.

In a further development of the invention it is provided that the first component half made of a light and radar translucent plastic, in particular thermoplastic, which is preferably selected from a group comprising polycarbonate (PC), polycarbonate blends, polymethyl methacrylate (PMMA), polyamide (PA), and a mixture of the aforementioned plastics.

According to a development of the invention, it is provided that the light and radar translucent casting compound used in method step b) is selected from a group comprising polyurethane, silicone, epoxy resin and a mixture of the above-mentioned casting compounds. This has the particular advantage that particularly inexpensive materials can be used.

In a further embodiment it is provided that the light and radar translucent casting compound according to method step b) has the same permittivity as the light and radar translucent plastic from which the first component half is made. This has the particular advantage that no further plastics are required to manufacture the radar cover.

In connection with the present invention, the term “permittivity” - denoted by ε and also called dielectric conductivity or dielectric function - is to be understood as the permeability of a material for electric fields.

In a further development of the invention it is provided that the light and radar translucent plastic is a light and radar transparent plastic. This has the particular advantage that the lighting in the first half of the component can be configured particularly advantageously.

In a further embodiment it is provided that the light and radar translucent casting compound according to method step b) is a light and radar transparent casting compound. This has the particular advantage that the radar waves pass through the second component half undisturbed.

The object is also achieved by creating a radar cover plate, the radar cover plate being able to be produced or being produced by a method according to the invention or by one of the previously described embodiments of the method. In connection with the radar cover plate there are in particular the advantages which have already been explained in connection with the method.

The invention is explained in more detail below with reference to the drawing.

• 1 eine aus dem Stand der Technik bekannte Radarabdeckplatte,
• 2 eine erfindungsgemäße Radarabdeckplatte,
• 3 ein Vergießen einer Vergussmasse gemäß Verfahrensschritt b), sodass eine zweite Bauteilhälfte entsteht,
• 4 eine Variante des Vergießens aus 3, wobei eine Kavität durch ein Vergusselement gebildet wird.

Show:

• 1 a radar cover plate known from the prior art,
• 2 a radar cover plate according to the invention,
• 3 casting a casting compound according to method step b), so that a second component half is formed,
• 4 a variant of shedding 3 , wherein a cavity is formed by a potting element.

1 shows a radar cover plate known from the prior art 1 , with the front half of the component 3 with the rear half of the component 9 over several beads of adhesive 15 connected is. Furthermore, in 1 a front 5 and a back 7 the first half of the component 3 as well as a front 11 and a back 13 the second half of the component 9 to see. Incidentally, is in 1 a radar sensor 17 to see. Furthermore, in 1 shown that around the glue beads 15 an air gap 19 It can be seen which is disadvantageous in terms of light and radar translucency or light and radar transparency.

Furthermore, the first half of the component 3 made of a light and radar translucent plastic 4 manufactured.

In 2 the same reference numerals designate comparable or similar parts as in 1 , which is why refer to the description of the figures 1 is referred. By the inventive method, which is still in connection with 3 and 4 is described in more detail, it turns out that on the adhesive beads 15 out 1 in 2 , ie the radar cover plate according to the invention, can be dispensed with and no air gaps 19 as in 1 can be seen, are recognizable.

Furthermore is 2 that the front 5 the first front half of the component 3 at least one Y heating wire 20 having. The first front component half is particularly preferred 3 by injecting a film 2 with, preferably a thin, at least one Y heating wire 20 made with a plastic, especially polycarbonate. The at least one Y heating wire is also in the 3 and 4 shown.

Furthermore, in 2 to recognize that at least one Z heating wire 22 on the back side 7 the first half of the component 3 is arranged and then the at least one Z heating wire 22 by means of heat, preferably by ultrasound, in the back 7 the first front half of the component 3 is introduced. The at least one Z heating wire 22 is also in the 3 and 4 shown.
Furthermore, it is preferably provided that the arrangement of the at least one Z heating wire 22 on the back side 7 the first half of the component 3 then occurs when the first half of the component 3 is very thin, in particular has a thickness of 1 to 15 mm, preferably 2 to 10 mm, particularly preferably 3 to 8 mm, particularly preferably 4 to 6 mm, with a method according to the invention preferably then being carried out.

In 3 The same reference numerals designate the same or similar parts as in 1 or 2 , which is why in this regard to the corresponding description of the figures 1 and 2 is referred.

In 3 it can first be seen that several X heating wires 21 (solid line in cross section) as well as several light guides 23 (dotted line in cross section) are shown. This arrangement is the result of arranging at least one X heating wire 21 on the back side 7 the first half of the component 3 in such a way that the radar cover plate obtained from the method 1 is heated, and / or arranging at least one light guide 23 on the back side 7 the first half of the component 3 in such a way that the radar cover plate obtained from the method 1 can be illuminated. In the 3 arrangement of the X heating wires shown 21 and the light guide 23 was carried out according to method step a). Subsequent to process step a) in process step b) is by casting the previously arranged X-heating wires 21 and / or the light guide 23 on the back side 7 the first half of the component 3 with a light and radar translucent casting compound 25 achieves that the previously arranged components become an integral part of the second component half 9 become. Furthermore, the potting takes place in such a way that the radar cover plate obtained from the method 1 has a uniform component thickness and around the arranged X heating wires 21 and / or light guides 23 no air gap 19 consists.

Furthermore, it is preferably provided that the at least one X heating wire 21 according to step a) is cast in step b) in such a way that the at least one X heating wire 21 directly in or in the area of the front 11 the second rear half of the component 9 located.

Still is 3 at least one delimiting element 24 to remove, causing the potting compound to flow away 25 is prevented.

In 4 is a process variant to that in 3 shown method, wherein by a casting element 27 a cavity 29 is formed, which then with the sealing compound 25 is filled out. The casting element 27 is preferably on the back 7 the first half of the component 3 placed, preferably also the first component half 3 with the front 5 is arranged downwards. Here is in the potting element 27 at least one entry opening 31 - whereby the potting compound 25 is filled - and at least one outlet opening 33 shown, whereby gases, especially air, from the cavity 29 can escape.

Furthermore, it is preferably provided that the first component half 3 is made of a light and radar translucent plastic, in particular thermoplastic, which is preferably selected from a group comprising polycarbonate (PC), polycarbonate blends, polymethyl methacrylate (PMMA), polyamide (PA) and a mixture of the aforementioned plastics.

Furthermore, it is preferably provided that the light and radar translucent casting compound used in method step b) or the casting 25 is selected from a group comprising polyurethane, silicone, epoxy resin and a mixture of the aforementioned casting compounds.

Furthermore, it is preferably provided that the light and radar translucent casting compound 25 has the same permittivity as the light and radar translucent plastic 4 , from which the first half of the component 3 is made. If this is not the case, the casting compound must have a different thickness at the locations of the decorative elements, which thickness can be determined via the difference in permittivity.

It is also preferably provided that the light and radar translucent plastic of the first component half 3 has self-healing properties. This has the particular advantage of having a scratch-resistant coating on the front 5 the first half of the component 3 can be dispensed with.

Furthermore, it is preferably provided that the light and radar translucent plastic 4 a light and radar transparent plastic 4 is.

It is also preferably provided that the light and radar translucent casting compound 25 a light and radar transparent potting compound 25 is.

Furthermore, it is preferably provided that by a corresponding design of the potting element 27 a three-dimensionally shaped outer material is also provided or filled with a potting compound.

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 102005015323 A1 [0003]
• DE 10248915 A1 [0004]
• DE 112015006455 T5 [0005]

Claims (9)

Method for producing a radar cover plate (1), comprising a first front component half (3) with a front (5) and a rear (7) and a second rear component half (9) with a front (11) and a rear (13 ), wherein the first component half (3) is made of a light and radar translucent plastic and has a decorative element (15), characterized in that the second component half (9) is produced by a method with the following steps, the second component half (9) with its front side (11) is inseparably connected to the rear side (7) of the first component half (3) during the method: a) arranging at least one X heating wire (21) on the rear side (7) of the first Component half (3) in such a way that the radar cover plate (1) obtained from the method can be heated, and / or arranging at least one light guide (23) on the back (7) of the first component half (3) in such a way that the from de Radar cover plate (1) obtained in the method can be illuminated, b) casting the at least one X heating wire (21) and / or at least one light guide (23) arranged in step a) on the back (7) of the first component half (3) with a Light- and radar-translucent casting compound (25) in such a way that the radar cover plate (1) obtained from the method has a uniform component thickness and none around the X-heating wires (21) and / or light guide (23) arranged according to method step a) Air gap (19) exists. Procedure according to Claim 1 , characterized in that an additional scratch-resistant coating on the front (5) of the first component half (3) is dispensed with. Procedure according to Claim 1 or 2 , characterized in that the first component half (3) is made of a light and radar translucent plastic (4), in particular thermoplastic, which is preferably selected from a group comprising polycarbonate (PC), polycarbonate blends, polymethyl methacrylate (PMMA ), Polyamide (PA) and a mixture of the aforementioned plastics. Method according to one of the preceding claims, characterized in that the light and radar translucent casting compound (25) used in process step b) is selected from a group comprising polyurethane, silicone, epoxy resin and a mixture of the aforementioned casting compounds. Method according to one of the preceding claims, characterized in that the light and radar translucent casting compound (25) according to method step b) has the same permittivity as the light and radar translucent plastic (4) from which the first component half ( 3) is made. Method according to one of the preceding claims, characterized in that the light and radar translucent plastic (4) of the first component half (3) has self-healing properties. Method according to one of the preceding claims, characterized in that the light and radar translucent plastic (4) is a light and radar transparent plastic (4). Method according to one of the preceding claims, characterized in that the light and radar translucent casting compound (25) according to method step b) is a light and radar transparent casting compound (25). Radar cover plate (1), producible or manufactured by a method according to one of the Claims 1 to 8th ,

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