JP4224794B2 - Manufacturing method of radio wave transmission cover - Google Patents

Description

  The present invention relates to a method of manufacturing a radio wave transmission cover that covers an opening portion where a radio wave radar is disposed on the back side of a vehicle exterior member of a vehicle on which a radio wave radar device such as a millimeter wave radar device or a microwave radar device is mounted. About.

  The auto-cruise system measures the distance and relative speed between the vehicle in front and the vehicle using sensors mounted in front of the vehicle, and controls the throttle and brake based on this information to accelerate and decelerate the vehicle. This is a technology to control the distance. In recent years, this auto-cruise system has attracted attention as one of the core technologies of the Intelligent Transport System (ITS) aiming to reduce traffic congestion and reduce accidents.

  In general, a laser radar or a radio wave radar is used as a sensor used in an auto cruise system. Among these, the radio wave radar transmits this radio wave using a microwave having a frequency of 300 MHz to 300 GHz and a wavelength of 1 m to 1 mm, and receives the radio wave reflected on the object. The distance between the vehicle ahead and the vehicle and the relative speed are measured from the wave difference. Among these microwaves, a millimeter wave having a frequency of 30 GHz to 300 GHz and a wavelength of 1 to 10 mm has a particularly short wavelength. Therefore, a radio wave radar using this millimeter wave can be miniaturized. It is often used as a conventional radar. In addition, since the reflection coefficient of a good conductor such as metal is large, the radio wave can be identified well, and has characteristics that are less susceptible to fog, snow, sunlight, etc. compared to a laser. Therefore, the radio wave radar using this radio wave is suitably used as an on-vehicle radar.

  The radio wave radar is generally disposed on the back side of the exterior member of the vehicle. However, metal plating is often applied to the front grill or the like of the exterior member, and it is difficult to satisfactorily transmit radio waves having a large metal reflection coefficient. In particular, the front grille has a structure with vents for air intake and does not have a uniform wall thickness. There is a difference in radio wave transmission speed between the thick part and it becomes difficult to obtain sufficient sensitivity of the radio wave radar.

  Under such circumstances, it is common to provide an opening through which radio waves can be transmitted at a part of the exterior member corresponding to a part where the radio wave radar is disposed. In the case where an opening is provided in the exterior member, radio waves can enter and exit through the opening. However, the appearance of the exterior member loses continuity due to the provision of the opening, and the inside of the vehicle, for example, the radio wave radar device and the engine room, is visually observed from the opening, and thus the appearance of the vehicle is impaired. There is a fear. Therefore, conventionally, a covering component formed so as to transmit radio waves is inserted into the opening of the exterior member, and the opening and the exterior member main body are given a sense of unity (see, for example, Patent Document 1). ). In addition, as described above, the front grill or the like of the exterior member is generally plated with metal, so that it is necessary to form a metallic luster on the design surface of the radio wave transmission cover by some means. Such metallic luster is generally formed by vapor deposition of indium. Since indium is vapor-deposited into minute islands and radio waves can be transmitted through the gaps between the island-like portions, both metallic luster and radio wave transmissivity can be obtained by vapor deposition of indium.

  The radar wave transmission cover disclosed in Patent Document 1 is formed by laminating a plurality of resin layers formed with unevenness, and a design surface is constituted by a metal layer deposited between the resin layers, and the front surface It gives the impression that the fin members of the grill are continuously present in the coated part.

  However, since such a radar wave transmission cover has a structure in which a plurality of resin layers and a metal layer deposited between the resin layers are laminated, there is a problem that many man-hours are required for molding. Further, in order to eliminate the unevenness of the entire radar wave transmission cover and to keep the wall thickness constant, high-precision molding is required. Furthermore, in order to form a design surface on a resin layer formed with unevenness, processes such as vapor deposition and painting are required. For example, when a design surface is formed by painting and vapor deposition, a mask process that masks surfaces other than the painted surface → a painting process that coats the painted surface → a drying process that dries the paint → a peeling process that removes the mask → vapor deposition A mask process for masking a surface other than the surface → a peeling process for removing the mask and a large number of processes are required. These processes increase as the desired design becomes more complicated, which increases the manufacturing cost.

  Also, in order to reduce wall thickness error due to molding accuracy, a separate metal layer can be laminated in the gap between the resin layers by in-mold molding, and the resin layer can also be formed by two-color molding. (For example, refer to Patent Document 2).

According to the method for producing a translucent resin product disclosed in Patent Document 2, it is possible to obtain a molded product having a constant thickness without requiring high-precision molding by forming the resin layer by two-color molding. is there. However, in the manufacturing method of Patent Document 2 as well, in order to form a design surface, it is necessary to perform coating and vapor deposition in the same manner as described above, and there is a problem that the manufacturing cost increases due to an increase in man-hours. .
JP 2000-344032 A JP 09-239775 A

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method of manufacturing a radio wave transmission cover that does not require high-precision molding and can reduce manufacturing costs.

A method of manufacturing a radio wave transmission cover that solves the above problem is a method of manufacturing a resin radio wave transmission cover that is attached to an opening of a vehicle exterior member and on which a radio wave radar device is disposed on the back side, forming a film forming step of forming a film with a design, a shaping step of shaping the film into a predetermined shape, one of the transparent resin layer and the substrate layer by placing the shaped films in a mold And a first molding step for forming the first molded body, and a second molding step for molding the other of the transparent resin layer and the base material layer on the film existing surface of the first molded body. And Hereinafter, this manufacturing method is referred to as a reference manufacturing method.

A method of manufacturing a radio wave transmission cover according to a first aspect of the present invention that solves the above problem is a method of manufacturing a resin radio wave transmission cover that is attached to an opening of a vehicle exterior member and has a radio wave radar device disposed on the back side. A film forming step for forming a film having a predetermined design, a shaping step for shaping the film into a predetermined shape, and the design of the film is formed by placing the shaped film in a mold. Forming a first molded body having a transfer surface onto which the design is transferred by forming one of the transparent resin layer and the base material layer on the surface and removing the film; And a second molding step of molding the other of the transparent resin layer and the base material layer on the transfer surface.

A method for manufacturing a radio wave transmission cover according to a second aspect of the present invention that solves the above problem is a method of manufacturing a resin radio wave transmission cover that is attached to an opening of a vehicle exterior member and has a radio wave radar device disposed on the back side. Film forming step for forming a film having a predetermined design, one of the transparent resin layer and the base material layer is molded, and the design of the film is formed on the transparent resin layer or the base material layer disposed in the mold A shaping process for forming a first molded body having a transfer surface onto which a design has been transferred by removing the shaped film, and forming a first shape with the surfaces facing each other shaped into a predetermined shape; And a second molding step of molding the other of the transparent resin layer and the base material layer on the transfer surface of the molded body.

A method for manufacturing a radio wave transmission cover according to a third aspect of the present invention that solves the above problem is a method of manufacturing a resin radio wave transmission cover that is attached to an opening of a vehicle exterior member and has a radio wave radar device disposed on the back side. Forming a film having a predetermined design, forming one of the transparent resin layer and the base material layer, and laminating the film on the transparent resin layer or the base material layer disposed in the mold A shaping step for forming the first molded body by shaping into a predetermined shape, a second molding step for molding the other of the transparent resin layer and the base material layer on the film existing surface of the first molded body, It is characterized by having.

  The radio wave cover manufacturing method of the present invention preferably includes any one of the following configurations (1) to (8).

  (1) The film has at least one of a printing surface having a predetermined design and a vapor deposition design surface on which a metal material whose crystal extends in the vapor deposition direction is vapor-deposited.

  (2) The film includes a bright piece having a vapor deposition design surface.

(3) The film has a film body having a printing surface having a predetermined design, and a bright piece having a vapor deposition design surface on which a metal material whose crystal extends in the vapor deposition direction is vapor-deposited. Forming a film body and a bright piece, forming the film body into a predetermined shape in the shaping step, and forming the shaped film body and the bright piece in the mold in the first molding step. by molding one of said transparent resin layer and the base layer forming the first molded body in a state of being disposed.

  (4) In the shaping step, the transparent resin layer or the base material layer is molded and a design surface having a predetermined design is formed on the surface.

(5)
(5-a) In the film forming step, both surfaces of the film are covered with a first cover film layer and a second cover film layer, and at least of the first cover film layer or the second cover film layer The layer on the transparent resin layer side is formed of a transparent resin.
(5-b) In the film forming step, both sides of the glitter piece are covered with the first cover film layer and the second cover film layer, and at least of the first cover film layer or the second cover film layer. Of these, the layer on the transparent resin layer side is formed of a transparent resin.
(5-c) In the film forming step, at least one of the film main body and the glitter piece is covered with a first cover film layer and a second cover film layer, and at least the first cover film layer Alternatively, the transparent resin layer side layer of the second cover film layer is formed of a transparent resin.

  (6) In the shaping step or the shaping step, the film is shaped by vacuum forming and pressure forming.

  (7) One of the molds used in the first molding step or the forming step is used in the second molding step, and the transparent resin layer and the base material layer are formed by two-color molding.

  (8) The metal material whose crystal extends in the vapor deposition direction is a metal material selected from indium, tin, and gold.

When the reference manufacturing method includes the configuration (1), since a desired design is configured by a printing surface or a vapor deposition design surface, a portion of the design that does not require metallic luster can be formed by printing. For this reason, a manufacturing man-hour can be reduced and a manufacturing cost can be reduced.

When the manufacturing method of the radio wave transmission cover of the first invention includes the configuration (1), in addition to the effects described above, only the printing surface and the vapor deposition design surface of the film are transferred. The familiarity between the decorative body layer including the vapor deposition design surface, the transparent resin layer, and the base material layer is improved, and defects such as peeling are more reliably prevented.

When the reference manufacturing method includes configurations (2) and (3), a portion of the design that does not require metallic luster can be formed by printing, so that the number of manufacturing steps can be reduced and the manufacturing cost can be reduced. Can be made. Furthermore, since the portion of the design that requires metallic luster is composed of a bright piece separate from the film, it is not necessary to deposit indium on the entire desired design, so the amount of indium required for deposition should be reduced. Manufacturing cost can be further reduced.

When the manufacturing method of the radio wave transmission cover according to the second aspect of the present invention includes the configurations (1) and (4), a part of the design is formed by coating or the like, so that it is manufactured as compared with the case where the whole is formed by vapor deposition. Man-hours are reduced and manufacturing costs are reduced.

  In addition, in the radio wave transmission cover manufactured by the manufacturing method of the present invention, when the decorative body layer includes a bright piece on which a metal material whose crystal extends in the vapor deposition direction is deposited, the metallic luster among the desired designs Only the necessary part can be constituted by a bright piece. For this reason, since it is not necessary to deposit a metal material whose crystal extends in the vapor deposition direction on the entire decorative layer, the amount of the metal material which the crystal extends in the vapor deposition direction required for vapor deposition can be reduced. Cost can be reduced.

  The radio wave transmission cover manufactured by the manufacturing method of the present invention is a resin radio wave that is attached to an opening of a vehicle exterior member and has a radio wave radar device such as a millimeter wave radar device or a microwave radar device arranged on the back side. It is a transparent cover. This radio wave transmission cover can be attached to, for example, a front grill, a bumper, a back garnish, a spoiler, a side molding, or the like. Further, the attachment of the radio wave transmission cover to the opening of the vehicle exterior member can be performed by, for example, a method such as adhesion or welding, or an engagement portion having a predetermined shape is provided at the end of the radio wave transmission cover. The engaging portion can be engaged with the opening of the vehicle exterior member. Moreover, it is not restricted to this, It can also be attached by a known various method.

  The radio wave transmission cover manufactured by the manufacturing method of the present invention includes a transparent resin layer having an exposed surface that is exposed on the outer surface of the radio wave transmission cover, a base material layer disposed apart from the transparent resin layer, and a transparent A decorative body layer that is laminated in a gap between the resin layer and the base material layer and displays a design on the outer surface of the radio wave transmission cover through the transparent resin layer.

  The radio wave transmission cover manufactured by the manufacturing method of the present invention is attached to the opening of the vehicle exterior member by a known method as described above. At this time, the exposed surface exposed on the outer surface of the radio wave transmitting cover is exposed on the outer surface side of the vehicle exterior member. Therefore, the transparent resin layer can be formed of a commonly used transparent resin having high weather resistance such as polycarbonate.

  A transparent resin can also be used for a base material layer, and black resins, such as AES and ASA, can also be used. Moreover, not only this but a known resin material can be used. When forming the decorating body layer mentioned later with transparent resin, it is preferable to form a base material layer with black resin. In this case, the portion of the decorative body layer on which the printing surface or the vapor deposition design surface is not formed can be displayed in black with a black resin, and the design of the decorative body layer can be visually recognized in three dimensions with contrast. can do. Furthermore, by forming the base material layer with a black resin, the radio wave radar device disposed on the back side of the radio wave transmission cover becomes difficult to be seen from the outside of the vehicle exterior member, for example, the front grille, etc. There is also an effect of improving the designability of.

  Moreover, when forming a transparent resin layer with a polycarbonate, it is desirable to form a base material layer with AES. This is because AES and polycarbonate have substantially the same dielectric constant, so that radio waves are transmitted better.

  The decorative body layer is laminated in the gap between the transparent resin layer and the base material layer, and displays the design on the outer surface of the radio wave transmission cover through the transparent resin layer. That is, since the transparent resin layer located on the outermost surface of the radio wave transmission cover is formed of a transparent resin, the design of the decorative body layer laminated on the lower layer of the transparent resin layer is the radio wave transmission cover through the transparent resin layer. Displayed on the outer surface of the. The decorative body layer can be formed by previously forming a resin material into a film shape and laminating it when forming a transparent resin layer or a base material layer.

  In the radio wave transmission cover manufactured by the manufacturing method of the present invention, the decorative body layer has a printing surface having a predetermined design and a vapor deposition design having a predetermined design in which a metal material having a crystal extending in the vapor deposition direction is vapor-deposited. A surface may be provided. Further, the decorative body layer may include a bright piece having a vapor deposition design surface. Various known materials can be used as the metal material in which the crystals extend in the vapor deposition direction, but the metal material selected from indium, tin, and gold is vapor deposited while the crystals that extend in the vapor deposition direction are sufficiently separated from each other. Therefore, it can be used more preferably. That is, since the crystals extending in the vapor deposition direction are vapor-deposited while being sufficiently separated from each other, radio wave transmission through the gaps between the crystals is performed better. For this reason, it is possible to obtain both metallic luster and good radio wave permeability by depositing these metals. Hereinafter, a metal material in which crystals extend in the vapor deposition direction is simply abbreviated as a metal material.

  The glitter piece can be formed by vapor-depositing a metal material on the surface of a resin plate made of a known resin material such as a transparent resin or a colored resin, and exhibits a metallic luster due to the vapor deposition of the metal material. The decorative body layer can be composed of only the glitter piece, or it can be composed of the glitter piece and a resin layer that supports the glitter piece. Further, depending on the desired design, a resin layer that supports the glitter piece can be formed in a film shape, and various designs can be printed on the film layer. When various designs are printed and formed on the film layer, the repeated steps of mask / vapor deposition or mask / painting / drying can be omitted, and the manufacturing process can be greatly reduced. In any case, it is desirable that the bright piece is formed smaller than the transparent resin layer and the base material layer. By forming the bright piece in a small size, it is possible to reduce the amount of metal material required for vapor deposition and to reduce the manufacturing cost. That is, in general, the vapor deposition of the metal material is performed by arranging the vapor deposition material and the metal material in the vacuum chamber. At this time, if the same vacuum chamber is used, the amount of the metal material used for one vapor deposition is constant regardless of the number of vapor deposition materials arranged in the vacuum chamber and the size of the vapor deposition surface of the vapor deposition material. . For this reason, if a large number of vapor deposition materials are arranged in the vacuum chamber, the amount of metal material used per vapor deposition material is reduced and the manufacturing cost is reduced. Therefore, by making the glitter pieces smaller than the transparent resin layer or the base material layer, the number of glitter pieces that can be arranged at once in the vacuum chamber increases, and the amount of metal material used per glitter piece decreases. Therefore, the manufacturing cost can be reduced. Here, since gold and indium are very expensive materials among the above-described metal materials, it is possible to significantly reduce manufacturing costs by reducing the amount of these materials used.

  An adhesive layer may be provided on at least one surface of the bright piece. By providing an adhesive layer on at least one surface of the bright piece, it is possible to improve the bonding between the bright piece and the film layer, the transparent resin layer, or the base material layer during molding, which will be described later. It becomes possible to do.

  When the bright piece is formed of a transparent resin, a black layer can be provided in the gap between the bright piece and the base material layer. In this case, the portion of the bright piece where the metal material is not vapor-deposited is displayed in black by the black layer, and the vapor-deposited design surface of the bright piece is visually recognized three-dimensionally with the contrast between the metallic luster and black. In the case where the decorative body layer is composed of a bright piece and a film layer, the black layer is disposed in the gap between the bright piece and the film layer and the base material layer.

  According to the radio wave transmission cover manufactured by the manufacturing method of the present invention, when the decorative body layer includes a bright piece, the bright piece can impart a metallic luster to the radio wave transmission cover. In the case where only the metal material is vapor-deposited, the amount of the metal material required for vapor-depositing one bright piece can be reduced, and the manufacturing cost can be reduced. Furthermore, when the design is printed on the film layer, the manufacturing process can be greatly reduced.

  In the radio wave transmission cover manufactured by the manufacturing method of the present invention, the decorative body layer can be covered with a first cover film layer and a second cover film layer on both sides. By making a decorating body layer into which both surfaces were covered with the 1st cover film layer and the 2nd cover film layer, the shape and design of a decorating body layer are the 1st cover film layer and the 2nd It can be protected with a cover film layer.

  That is, the decorative body layer is formed by forming a predetermined design on a substrate or film made of a resin material by vapor deposition or printing. For this reason, when a thermoplastic resin or the like that is plasticized at a relatively low temperature is used as a resin material, a film or a substrate may be thermally deformed by heating the decorative layer during molding of the radio wave transmission cover. is there. When a film, a substrate, or the like is thermally deformed, a design formed by vapor deposition, printing, or the like is also deformed together with the resin, and the design of the obtained radio wave transmitting cover may not match the desired design. However, in the case where the decorative body layer is covered with the first cover film layer and the second cover film layer, the decorative body layer is formed by the first cover film layer and the second cover film layer. Since it is protected and hardly deforms by heat, the design of the radio wave transmission cover can be made better regardless of the type of resin constituting the decorative body layer. At this time, at least the layer on the transparent resin layer side of the first cover film layer and the second cover film layer is formed of a transparent resin, so that the design by the decorative body layer is placed outside the radio wave transmission cover. It will be displayed well.

The reference manufacturing method includes a film forming step, a shaping step, a first forming step, and a second forming step.

  The film forming step is a step of forming a film having a predetermined design. At least one of a printing surface having a predetermined design and a vapor deposition design surface on which a metal material is vapor-deposited can be formed on this film (Configuration (1)). A film can be formed using normal resin materials, such as PMMA, PET, and polyamide. The printing surface can be formed by a usual method such as gravure printing. The vapor deposition design surface can be performed by a normal method such as vacuum vapor deposition. When a printing surface and a vapor deposition design surface are formed on a film, either printing on the film or vapor deposition of a metal material may be performed first, but a process such as masking the printing surface during vapor deposition is performed. It is preferable to add appropriately. The printing surface and the vapor deposition design surface can also be provided on the same surface of the film. When the film is formed of a transparent resin, it can be provided on two opposing surfaces.

  The shaping step is a step of shaping the film into a predetermined shape. This shaping step is a step of shaping the film formed in the above-described film forming step into a desired shape. By shaping the film in this step, irregularities can be imparted to the film so that the film can be viewed three-dimensionally. When forming a film printing surface or a vapor deposition design surface, irregularities can be imparted to the printing surface or vapor deposition design surface formed on the film. The shaping can be performed by a usual method such as vacuum forming or pressure forming. By this shaping step, the film becomes a decorative body layer.

A 1st shaping | molding process is a process of arrange | positioning the shaped film in a shaping | molding die, shape | molding one of a transparent resin layer and a base material layer, and forming a 1st molded object. In the first molding step, one of the transparent resin layer and the base material layer is molded on one side of the shaped film to form a first molded body having a film existing surface on which the film is exposed. Is done. In addition, since the transparent resin layer or the base material layer is filled between the irregularities on one side of the film formed in the irregularity and formed in the irregularization step in the first molding step, the formed transparent resin layer or The base material layer has a planar surface shape.

The second molding step is a step of forming the other of the transparent resin layer and the substrate layer on the film existing surface of the first molded body. That is, the second molding step is a step of forming the base material layer when the transparent resin layer is formed in the first molding step, and the base material layer is formed in the first molding step. Is a step of forming a transparent resin layer.

  By this second molding step, the transparent resin layer or the base material layer is filled also between the irregularities on the other surface of the shaped film to form a planar surface shape. For this reason, the thickness of the radio wave transmission cover can be easily made substantially constant by the first molding step and the second molding step described above. A radio wave transmission cover in which a film, that is, a decorative body layer is laminated in the gap between the transparent resin layer and the base material layer is formed by the first molding process and the second molding process.

According to the reference manufacturing method, since the transparent resin layer is formed on one surface of the film layer and the base material layer is formed on the other surface, the thickness of the radio wave transmission cover composed of the film layer, the transparent resin layer and the base material layer is reduced. Can be easily constant. In addition, when the reference manufacturing method has the configuration (1), a part of the design is formed by printing, which reduces the number of manufacturing steps by reducing repeated steps of mask / vapor deposition or mask / painting / drying. Manufacturing costs are reduced.

The manufacturing method of the radio wave transmission cover of the first invention is a method having the same film formation process and shaping process as the reference manufacturing method, and the first molding process and the second molding process are different from the reference manufacturing method.

In the method for manufacturing the radio wave transmission cover of the first invention, the first molding step, and the shaping has been film was placed in a mold transparent resin layer on a surface design is formed of the film and the substrate layer And forming a first molded body having a transfer surface on which a design is formed by removing one of the films and removing the film. In the case of forming the printed surface and deposited design surface on the film (Configuration (1)), while the formation of the transparent resin layer and the base layer to the printed surface of the film, by removing the film, the printed surface Ya A first molded body having a transfer surface onto which the vapor deposition design surface is transferred is formed. The second molding step is a step of forming the other of the transparent resin layer and the base layer to the transfer surface of the first molded body.

In the method for manufacturing the radio wave transmission cover of the first invention, the film is intended to face being design is formed peelably formed, a transparent resin layer on a surface design is formed of the film and the base layer By removing the film after forming one of these, the design is transferred to the transparent resin layer or the base material layer to form a transfer surface. When a printing surface or a vapor deposition design surface is formed on a film, a printing surface composed of the printing surface or the vapor deposition design surface may be formed so as to be peelable. In this case, the printing surface and the vapor deposition design surface are transferred to the transparent resin layer or the base material layer by removing the film after forming one of the transparent resin layer and the base material layer on the printing surface side of the film. Form a transfer surface. Accordingly, the film used in the method for manufacturing a radio wave transmission cover according to the first invention is preferably a film in which a layer including a design such as a printing surface or a vapor deposition design surface is bonded to the film body with, for example, an adhesive layer. .

According to the manufacturing method of the radio wave transmission cover of the first invention , the transparent resin layer is formed on one surface of the film layer and the base material layer is formed on the other surface, as in the reference manufacturing method. The thickness can be easily made constant. Moreover, when the manufacturing method of the radio wave transmission cover according to the first invention includes the configuration (1), a part of the design is formed by printing, so that the repeated steps of mask / vapor deposition or mask / painting / drying are reduced. As a result, the number of man-hours for vapor deposition is reduced, and the manufacturing cost is reduced. Furthermore, since only the layer containing the design (the layer having the transfer surface) is transferred from the film, the layer having the transfer surface, that is, the familiarity between the decorative body layer, the transparent resin layer, and the base material layer is improved, and peeling is performed. Etc. are more reliably prevented.

When the reference manufacturing method includes configurations (2) and (3), in the film forming step, a film having a predetermined design is formed and a bright piece having a vapor deposition design surface on which a metal material is vapor-deposited is formed. The first forming step forms a first molded body by molding one with the shaped films with bright piece and the transparent resin layer and the base layer in a state of being placed into the mold to.

Configuration Reference production method (2), if provided with (3), since the film and glitter pieces are those formed separately, the film and at least one in the film and bright pieces of the bright strip It is preferable to provide an adhesive layer to be bonded.

When the reference production method includes the configurations (2) and (3), the transparent resin layer is formed on one surface of the film and the base material layer is formed on the other surface. The thickness of the radio wave transmission cover made of layers can be easily made constant. Furthermore, by making the glitter pieces small, a large number of glitter pieces can be formed by a single vapor deposition, and the amount of metal material required to produce one glitter piece can be reduced, reducing the manufacturing cost. Can be made.

The manufacturing method of the radio wave transmission cover of the second invention has the same second molding step as the manufacturing method of the radio wave transmission cover of the first invention . The method for manufacturing a radio wave transmission cover according to the second aspect of the invention has a forming step instead of the forming step and the first forming step.

In the method for manufacturing a radio wave transmission cover according to the second invention , the film forming step is a step of forming a film having a predetermined design. In the forming process, one of the transparent resin layer and the base material layer is molded, and the surface on which the film design is formed is opposed to one of the transparent resin layer and the base material layer arranged in the mold. Then, the first molded body to which the design has been transferred is formed by removing the shaped film. When the manufacturing method of the radio wave transmission cover of the second invention includes the configuration (4), a design surface having a predetermined design is formed on one surface of the transparent resin layer and the base material layer in the forming step. .

On the formation of the design surface to one of the deposition design surface only formed transparent resin layer and the base layer to the film, vapor deposition design surface of the one in the film with the transparent resin layer design surface is formed with the substrate layer When transferring, at least the vapor deposition design surface can be easily formed by transfer.

In the method for manufacturing a radio wave transmission cover according to the second aspect of the invention , the design surface formed on one of the transparent resin layer and the base material layer constitutes a decorative body layer of the radio wave transmission cover together with the transferred design. The design surface can be formed by a known method such as painting or coating. In addition, when a design surface is formed on the transparent resin layer, a mask is formed on a portion where the design is transferred to form the design surface so that the transferred design can be displayed well on the outside of the radio wave transmission cover. be able to.

In the method for manufacturing a radio wave transmission cover according to the present invention, in the film forming step, at least one side selected from a film, a film body, and a bright piece is covered with a first cover film layer and a second cover film layer. Can do. In this case, as described above, since at least one selected from the film, the film body, and the glitter piece is protected by the first cover film layer and the second cover film layer, the film, the film body, and the glitter piece are configured. Regardless of the type of resin, the design of the radio wave transmission cover is improved. Further, at this time, at least the layer on the transparent resin layer side of the first cover film layer and the second cover film layer is formed of a transparent resin in the same manner as described above. Will be displayed well on the outside. Here, at least one side selected from a film, a film main body, and a bright piece refers to both sides of a film only in the reference manufacturing method , the first invention, and the second invention . In addition, when the reference production method includes the configurations (2) and (3), the glitter integrated with the both sides of the film (film body) and the glitter piece, or the film body and the film body by bonding or the like. It refers to both surfaces of a single piece with a piece.

  Here, the film (or the film body and the bright piece) and the first cover are covered with the first cover film layer and the second cover film layer by covering at least one side selected from the film, the film body, and the bright piece. The thickness of the film member which consists of a film layer and a 2nd cover film layer becomes thick. For this reason, it may become difficult to shape the film member by the shaping process or the shaping process. In this case, by forming the film member by vacuum forming and pressure forming, the film member and the film which is a part of the film member can be easily formed into a desired shape. In the shaping process or the shaping process, the gap between the shaping mold having the shaping surface of the pair of molding dies and the film is vacuumed, and the other molding is performed by sucking the film in the direction of the shaping mold. By forming in combination with pressure forming that presses the film in the direction of the shaping mold and presses the film in the direction of the shaping mold, at least the adhesion of the film member to the shaping mold is improved. Even a film member can be easily shaped into a desired shape. Moreover, in this case, a slight gap can be provided in the thickness direction of the mold surface for shaping the step in the film member of the shaping mold. In this case, the air remaining in the gap between the film member and the shaping mold moves to this gap during shaping, so that the adhesion between the film member and the shaping portion is further improved, and the thick film member is shaped. The shape can be made with higher accuracy.

  Furthermore, the mold surface for shaping the step in at least the film member of the shaping mold can be formed of a material having open pores. In this case, similarly, the air remaining in the gap between the film member and the shaping mold moves to the pores during shaping, so that the thick film member can be shaped with higher accuracy. When both sides of the film are not covered with the first cover film layer and the second cover film layer, or when only one side of the film is covered, the thickness of the film and the thickness of the film member are not so thick. . Therefore, in this case, the shaping step or the shaping step can be performed by only one of vacuum forming and pressure forming.

  In the method for manufacturing a radio wave transmission cover according to the present invention, one of the molding dies used in the first molding step or the forming step is also used in the second molding step, and the transparent resin layer and the base material layer are formed by two-color molding. It can also be formed.

  By forming the transparent resin and the base material layer by two-color molding, the second molding step is performed while the transparent resin layer or the base material layer formed in the first molding step or the shaping process is placed in the mold. be able to. For this reason, since the other layer is laminated without cooling the transparent resin layer or the base material layer formed in the first molding step or the forming step, the transparent resin layer and the base material layer The temperature difference is reduced and peeling between the transparent resin layer and the base material layer due to the difference in expansion coefficient is prevented. Therefore, it is possible to reduce the manufacturing cost by reducing the manufacturing loss of the radio wave transmission cover due to peeling. Furthermore, since there is no need to take out the transparent resin layer or the base material layer formed in the first molding process or the shaping process from the mold, there is a problem such that the printing surface or the vapor deposition design surface peels off during the work. The manufacturing cost is further reduced because the manufacturing loss due to this is prevented and the manufacturing loss due to this is prevented.

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

(Example 1)
The radio wave transmission cover of Example 1 is an example of the radio wave transmission cover obtained by the radio wave transmission cover manufacturing method of the present invention. In the radio wave transmission cover of the first embodiment, a decorative body layer is constituted by the bright piece on which the vapor deposition design surface is formed and the film on which the printing surface is formed. A schematic perspective view showing the radio wave transmission cover of the first embodiment is shown in FIG. 1, and a cross-sectional view taken along the line AA ′ in FIG. 1 is shown in FIG.

  The radio wave transmission cover 1 of Example 1 includes a transparent resin layer 2, a decorative body layer 3 laminated on the lower layer of the transparent resin layer 2, and a base material layer 4 laminated on a lower layer of the decorative body layer 3. And have.

  The decorative body layer 3 includes a small glitter piece 5 and a film 7 in contact with the glitter piece 5. The bright piece 5 is formed in a substantially elliptical flat plate shape made of PMMA, and an evaporation design surface 8 is formed on one surface thereof by depositing indium so as to be an emblem design. Further, the film 7 is formed using PMMA as a material, and on one surface thereof, a pseudo fin portion 10 having a fin-like design of the front grille is gravure-printed in a stripe shape to form a printing surface 11. In addition, the film 7 is shaped along the design of the striped pseudo fin portion 10, and two concave portions 12 and three convex portions 13 are alternately formed.

  A transparent resin layer 2 made of polycarbonate is formed on the upper layer of the decorative body layer 3, that is, on the upper layer side of the printing surface 11 of the film 7 and the vapor deposition design surface 8 of the bright piece 5. In addition, a base layer 4 made of AES resin is formed on the lower layer side of the decorative body layer 3, that is, on the lower layer side of the printing surface 11 of the film 7 and the vapor deposition design surface 8 of the bright piece 5, separated from the transparent resin layer 2. Has been. Since the transparent resin layer 2 and the base material layer 4 are filled also between the irregularities of the film 7 shaped so as to have irregularities, the radio wave transmission cover 1 of Example 1 is formed with a constant thickness. .

  In addition, a portion of the design displayed on the decorative body layer 3 that does not require metallic luster is constituted by a printing surface 11 by gravure printing, so that mask / vapor deposition or mask / painting / drying can be performed when forming this portion. Repeating steps can be reduced, and manufacturing costs can be reduced.

  Further, the design of the portion that requires metallic luster is composed of the glitter piece 5, and since the glitter piece 5 is small, when the design is deposited on the glitter piece 5, a large number of glitter pieces 5 are provided in the vacuum chamber. The amount of indium required for vapor deposition per bright piece 5 is reduced, and the manufacturing cost is further reduced.

( Reference Example 1 )
The manufacturing method of the radio wave transmission cover of Reference Example 1 is an example of a reference manufacturing method . The manufacturing method of the radio wave transmission cover of Reference Example 1 includes the configuration (1). 3 to 6 are schematic views showing a method for manufacturing the radio wave transmission cover according to the first reference example .

The manufacturing method of the radio wave transmission cover of Reference Example 1 is performed by a film forming process, a shaping process, a first molding process, and a second molding process.

The film forming step is a step of forming a film 17 having a printing surface 15 having a predetermined design and a vapor deposition design surface 16 on which indium is vapor-deposited. A schematic diagram showing the film forming process of the present Reference Example 1 is shown in FIG. In this film forming step, first, the pseudo fin portion 18 having the fin-like design of the front grille is printed in a striped pattern on the PMMA film 17 by gravure printing to form the printing surface 15. Next, the printing surface 15 of the film 17 and the surface of the vapor deposition design surface 16 on which no indium is vapor-deposited are masked by the mask material 20, and the film 17 is placed in the vacuum chamber to form the emblem design by vapor deposition. To do. This vapor deposition is performed once to several times depending on the desired design, and the mask with the mask material 20 is performed once to several times in the same manner as the vapor deposition. In this reference example 1 , the printing surface 15 and the vapor deposition design surface 16 are formed on the same surface of the film 17 by this film forming process.

The shaping step is a step of shaping the film 17 into a predetermined shape. FIG. 4 shows a schematic diagram illustrating the shaping process of Reference Example 1 . In this shaping process, the first mold 21 and the second mold 22 are arranged to face each other, and the film 17 in which the printing surface 15 and the vapor deposition design surface 16 are formed in the mold in the film forming process. The film 17 is formed into a shape corresponding to the mold surface 23 of the second mold 22 by arranging and vacuum forming in the direction of the second mold 22 that is a shaping mold. At this time, since the second mold 22 is formed so that the portion of the pseudo fin portion 18 protrudes in the printing surface 15 of the film 17, the portion of the pseudo fin portion 18 protrudes from the film 17. It will be shaped into the uneven shape.

The first forming step is a step of forming a first molded body by molding one of the transparent resin layer and the substrate layer by placing the film 17, which is shaped into the mold. FIG. 5 shows a schematic diagram illustrating the first molding process of the first reference example . In the first molding step of the present reference example 1 , the molten polycarbonate is injected into the gap between the film 17 shaped in the above-described shaping step and the first molding die 21 to form the transparent resin layer 25. Thus, a first molded body 29 composed of the film 17 and the transparent resin layer 25 was formed. Here, the film 17 has a printing surface 15 and a vapor deposition design surface 16, and constitutes a decorative body layer 27 of the radio wave transmission cover 26.

The second molding step is a step of forming the other of the transparent resin layer and the substrate layer on the film existing surface 28 of the first molded body 29. FIG. 6 shows a schematic diagram illustrating the second molding process of the first reference example . In the second molding step of the present reference example 1 , the second molding die 22 is opened and replaced with a third molding die 31 for molding the base material layer 30, and the film existing surface 28 of the first molded body 29 is replaced. A base material layer 30 was formed by injecting molten AES resin into the gap between the mold surface and the mold surface of the third mold 31.

In the method for manufacturing the radio wave transmission cover 26 according to the first reference example, the radio wave transmission cover 26 is formed by the film forming process to the second molding process described above. In the method of Reference Example 1 , since the transparent resin layer 25 is formed on one surface of the film 17 and the base material layer 30 is formed on the other surface, the film 17, the transparent resin layer 25 and the base material layer 30 are formed. The thickness of the radio wave transmission cover 26 can be easily made constant. In addition, a part of the design is formed by vapor deposition, and the other part is formed by printing, so that the repeated steps of mask / vapor deposition or mask / painting / drying are reduced, reducing the number of manufacturing steps and reducing the production cost. Is done.

Moreover, in this reference example 1 , the 1st shaping | molding die 21 is used also in a 2nd shaping | molding process among the shaping | molding dies used at a 1st shaping | molding process, and the transparent resin layer 25 and the base material layer 30 are formed by two-color shaping | molding. Therefore, the radio wave transmission cover 26 with good adhesion between the transparent resin layer 25 and the base material layer 30 and without peeling is formed.

( Example 2 )
The manufacturing method of the radio wave transmission cover of Example 2 is an example of the manufacturing method of the radio wave transmission cover of the first invention . The manufacturing method of the radio wave transmission cover of Example 2 includes the configuration (1). Schematic diagrams showing a method for manufacturing the radio wave transmission cover of Example 2 are shown in FIGS.

As shown in FIG. 7, the film 33 formed in the film forming process in Example 2 is formed with an adhesive layer 37 in advance before forming the printing surface 34 and the vapor deposition design surface 35 on the film 33. The printing surface 34 and the vapor deposition design surface 35 are formed on the adhesive layer 37. This adhesive layer 37 makes it possible to form a transfer surface 38 in a first molding step described later. In the manufacturing method of the radio wave transmission cover according to the second embodiment , the shaping process is performed in the same manner as in Reference Example 1, and the first molding process and the second molding process are performed as follows.

In the first molding step, the shaped film 33 is placed in a molding die, one of the transparent resin layer and the base material layer is formed on the printing surface 40 of the film 33, and the film 33 is removed to remove the printing surface. 34 and a first molded body 43 having a transfer surface 38 onto which the vapor deposition design surface 35 is transferred. FIG. 8 is a schematic diagram showing the first molding process of the second embodiment . In the first molding step of the second embodiment, the film 33 on which the printing surface 34 and the vapor deposition design surface 35 are formed is arranged so that the printing surface 40 is on the first molding die 45 side. The transparent resin layer 41 is formed by injecting molten polycarbonate into the gap between the surface 40 and the mold surface 46 of the first mold 45. Thereafter, the second molding die 47 is opened and the film 33 is removed to transfer a part of the adhesive layer 37, the printing surface 34, and the vapor deposition design surface 35 to the transparent resin layer 41, thereby transferring the transfer surface 38. The 1st molded object 43 which has was formed.

The second molding step is a step of forming the other of the transparent resin layer and the base layer to the transfer surface 38 of the first molded body 43. FIG. 9 shows a schematic diagram illustrating the second molding process of the second embodiment . In the second molding step of the second embodiment, the third molding die 48 for forming the base material layer 42 is disposed on the mold surface 46 of the first molding die 45 so as to face the first molding die 45. The base material layer 42 was formed by injecting molten AES resin into the gap between the transfer surface 38 of the first molded body 43 and the mold surface 50 of the third mold 48.

In the method for manufacturing the radio wave transmission cover according to the second embodiment, the radio wave transmission cover 51 is formed by the film forming process to the second molding process described above. Since the transparent resin layer 41 is formed on one surface of the decorative body layer 44 including the transferred printing surface 34 and the vapor deposition design surface 35, and the base material layer 42 is formed on the other surface, the decorative body layer 44, transparent The thickness of the radio wave transmission cover 51 including the resin layer 41 and the base material layer 42 can be easily made constant. In addition, a part of the design is formed by vapor deposition, and the other part is formed by printing, so that the repeated steps of mask / vapor deposition or mask / painting / drying are reduced, reducing the number of manufacturing steps and reducing the production cost. Is done. And since the transparent resin layer 41 and the base material layer 42 are formed by two-color molding, the first molding die 45 is used in the second molding step among the molding dies used in the first molding step. The radio wave transmission cover 51 with good adhesion between the resin layer 41 and the base material layer 42 without peeling is formed.

Furthermore, according to the manufacturing method of the radio wave transmission cover 51 of the second embodiment , only the printing surface 34 and the vapor deposition design surface 35 of the film 33 are transferred, so that the decoration including the transferred design surface and the vapor deposition design surface 35 is provided. The familiarity between the body layer 44, the transparent resin layer 41, and the base material layer 42 is improved, and problems such as peeling are more reliably prevented.

( Reference Example 2 )
The manufacturing method of the radio wave transmission cover of Reference Example 2 is an example of a reference manufacturing method . The manufacturing method of the radio wave transmission cover of Reference Example 2 includes configurations (2) and (3). 10 to 11 are schematic views showing a method for manufacturing the radio wave transmission cover of Reference Example 2 . In the present Reference Example 2 , the shaping step and the second molding step are performed in the same manner as in Reference Example 1 . A film formation process and a 1st shaping | molding process are performed as follows.

The film forming step is a step of forming a bright piece 56 having a vapor deposition design surface 55 on which indium is vapor-deposited while forming a film 53 having a printing surface 52 having a predetermined design. That is, in Reference Example 2 , only the printing surface 52 is formed on the film 53, and the vapor deposition design surface 55 is formed on the surface of the bright piece 56 that is separate from the film body 53. A schematic diagram showing the film forming process of Reference Example 2 is shown in FIG.

In the film forming step, the bright piece 56 is formed in a substantially elliptical flat plate shape made of PMMA, and indium is vapor-deposited on one surface so as to be an emblem design, thereby forming a vapor deposition design surface 55. . Further, the film body 53 is formed in the same manner as in Reference Example 1, and only the printing surface 52 by gravure printing is formed. An adhesive layer 57 is formed on the surface of the glitter piece 56 facing the vapor deposition design surface 55, and the glitter piece 56 is attached to and integrated with the film body 53 through the adhesive layer 57. The glitter piece 56 and the film body 53 formed in the film forming step are shaped in the same manner as in the shaping step of Reference Example 1 and are formed in an uneven shape.

In the first molding step, the first molded body 61 by molding one of the transparent resin layer and the substrate layer in a state of arranging a film body 53 and the bright pieces 56 shaped in the mold form Is done. FIG. 11 shows a schematic diagram illustrating the first molding process of the reference example 2 . In the first molding step, a transparent resin layer 58 is formed on the bright pieces 56 and the film body 53 by the same method as in Reference Example 1 .

According to the radio wave transmission cover manufacturing method of Reference Example 2 , since the transparent resin layer 58 is formed on one surface of the film body 53 and the base material layer is formed on the other surface, the film body 53, the bright piece 56, the transparent The thickness of the radio wave transmission cover including the resin layer 58 and the base material layer can be easily made constant. In addition, since a part of the design is formed by printing, the repeated steps of mask / vapor deposition or mask / painting / drying are reduced, the number of manufacturing steps is reduced, and the manufacturing cost is reduced.

  Furthermore, by making the bright piece 56 small, it is possible to form a large number of bright pieces 56 by a single vapor deposition, and to reduce the amount of indium required for manufacturing one bright piece 56, thereby reducing the manufacturing cost. Can be reduced.

( Example 3 )
The manufacturing method of the radio wave transmission cover of Example 3 is an example of the manufacturing method of the radio wave transmission cover of the second invention . The manufacturing method of the radio wave transmission cover of Example 3 includes configurations (1) and (4). Schematic diagrams illustrating a method for manufacturing the radio wave transmission cover of the third embodiment are shown in FIGS.

In Example 3 , the second molding step is performed in the same manner as Example 2 . In Example 3 , the film 60 formed in the film forming process does not have the printing surface 34 of the film 33 formed in the film forming process of Example 2 . In Example 3 , the forming process is performed as follows.

  First, the first molding die 64 and the second molding die 62 are opposed to each other, and molten polycarbonate is injected into the gap between the first molding die 64 and the second molding die 62 to mold the transparent resin layer 63. To do. At this time, the surface of the transparent resin layer 63 is formed in a concavo-convex shape in which the pseudo fin portion planned portion 65 where the pseudo fin portion is formed is recessed. Next, as shown in FIG. 12, a coating surface is coated on the pseudo fin portion planned portion 65 in the surface of the transparent resin layer 63 to form a design surface 66. At this time, since the mask is applied to the transfer planned portion 68 to which the vapor deposition design surface 67 of the film 60 is transferred, the transfer planned portion 68 of the molded transparent resin layer 63 is a portion where the design surface 66 is not formed. It becomes. Next, the vapor deposition design surface 67 of the film 60 is arranged to face the design surface 66 of the transparent resin layer 63, and the film 60 is shaped by pressure forming. Then, by removing the shaped film 60, a part of the adhesive layer 69 and the vapor deposition design surface 67 are transferred to the transfer scheduled portion 68 of the transparent resin layer 63, and the transfer surface 70 is transferred as shown in FIG. And the 1st molded object 71 with the design surface 66 is formed.

According to the manufacturing method of the radio wave transmission cover of the third embodiment , the transparent resin layer 63 is formed on one surface of the decorative body layer 72 including the transferred vapor deposition design surface 67 and the coated design surface 66, and on the other surface. Since the base material layer is formed, the thickness of the radio wave transmission cover including the decorative body layer 72, the transparent resin layer 63, and the base material layer can be easily made constant. In addition, part of the design is formed by vapor deposition and the other part is formed by coating, reducing the number of repeated steps of mask / vapor deposition or mask / painting / drying compared to forming the entire design by vapor deposition. Thus, the number of manufacturing steps is reduced and the manufacturing cost is reduced. Furthermore, since only the vapor deposition design surface 67 of the film 60 is transferred, the familiarity between the decorative body layer 72 including the transferred vapor deposition design surface 67, the transparent resin layer 63, and the base material layer is improved, and peeling, etc. Defects are more reliably prevented.

( Reference Example 3 )
The manufacturing method of the radio wave transmission cover of Reference Example 3 is an example of a reference manufacturing method , in which both sides of the film are covered with the first cover film layer and the second cover film layer in the film forming process, and the shaping process The method is the same as in Reference Example 1 except that vacuum forming and pressure forming are used. Schematic diagrams showing a method for manufacturing the radio wave transmission cover of Reference Example 3 are shown in FIGS.

The film forming step is a step of forming the first cover film layer 75 and the second cover film layer 76 made of PMMA on both surfaces of the film 73 formed in the same manner as in Reference Example 1 . The first cover film layer 75 and the second cover film layer 76 are laminated on both surfaces of the film 73 by a laminating method. By this film forming step, a film member 77 including the film 73, the first cover film layer 75, and the second cover film layer 76 is formed.

The shaping step is performed using the second mold 78 made of alumina having open-cell pores as the shaping mold. FIG. 14 is a schematic diagram showing the shaping step of the present Reference Example 3 , and FIG. 15 is an enlarged view of the main part of the second mold 78 and the film member 77 in FIG.

  Since the second mold 78 that is a shaping mold has open pores, air remaining in the gap between the film member 77 and the second molding mold 78 moves to the pores during shaping. For this reason, the thick film member 77 is shaped with higher accuracy. Furthermore, in this shaping step, the thick film member 77 can be shaped into a desired shape by vacuum forming the film member 77 in the direction of the second mold 78 and pressure forming.

In the third reference example , a parting surface 82 that forms a step on the film member 77 of the mold surface 80 of the second mold 78 is provided with a parting portion 82 that is a vertical surface. By arranging the boundary portion 87 between the vapor deposition design surface 83 and the printing surface 85 of the film member 77 and the colorless surface 86 that is not printed or vapor-deposited on the parting portion 82, the parting portion 82 is formed. It becomes difficult to see from the front of the radio wave transmission cover. Therefore, the design of the radio wave transmission cover is further improved. In addition, even when the shaping accuracy is relatively low and a deviation occurs between the boundary portion 87 and the unevenness formed by shaping, if the deviation of the boundary portion 87 is within the length of the parting portion 82, the boundary The part 87 is disposed in the parting part 82 and is not easily seen from the front of the radio wave transmission cover. Therefore, high accuracy is not required for shaping, and production can be performed more easily. Furthermore, the present invention is not limited to this, and the boundary portion 87 between the vapor deposition design surface 83 and the printing surface 85 and the colorless surface 86 can be changed stepwise as shown in FIG. In this case, even if the boundary portion 87 is arranged slightly protruding from the parting portion 82 and shaping is performed, since the boundary portion 87 itself is blurred, the deviation in shaping is not so noticeable. It can be done more easily.

According to the method for manufacturing a radio wave transmission cover of Reference Example 3 , in addition to the effect of the method for manufacturing the radio wave transmission cover of Reference Example 1 , an effect of further improving the design of the radio wave transmission cover can be obtained. That is, by forming the first cover film layer 75 and the second cover film layer 76 on both surfaces of the film 73, the film 73 is protected by the first cover film layer 75 and the second cover film layer 76. . For this reason, for example, even when shaping is performed at a high temperature and the film 73 is exposed to a high temperature, the deformation of the film 73 is suppressed and the design of the radio wave transmission cover is further improved. Further, since the shaping step is performed by vacuum forming and pressure forming, a thick film member 77 in which the first cover film layer 75 and the second cover film layer 76 are laminated on both surfaces of the film 73 is shaped. In this case, the shaping can be performed with high accuracy. Furthermore, by forming the second molding die 78, which is a shaping mold, having open-celled pores, the thick film member 77 can be shaped with higher accuracy.

It is a model perspective view which shows the electromagnetic wave transmission cover of Example 1 of this invention. It is sectional drawing of A-A 'in FIG. 6 is a schematic diagram illustrating a film forming process of Reference Example 1. FIG. It is the schematic showing the shaping process of the reference example 1. FIG. 6 is a schematic diagram illustrating a first molding process of Reference Example 1. FIG. 10 is a schematic diagram illustrating a second molding process of Reference Example 1. FIG. It is a schematic diagram showing the film formed at the film formation process of Example 2 of this invention. It is the schematic showing the 1st shaping | molding process of Example 2 of this invention. It is the schematic showing the 2nd shaping | molding process of Example 2 of this invention. It is the schematic showing the film formation process of the reference example 2 . 10 is a schematic diagram illustrating a first molding process in Reference Example 2. FIG. It is the schematic showing the shaping process of Example 3 of this invention. It is the schematic showing the shaping process of Example 3 of this invention. It is the schematic showing the shaping process of the reference example 3. FIG. FIG. 6 is an enlarged view of main parts of a second mold 78 and a film member 77. It is a principal part enlarged view showing the other example of a boundary part.

Explanation of symbols

1: Radio wave transmission cover 2: Transparent resin layer 3: Decorating body layer 4: Base material layer 5: Bright piece 7: Film 8: Deposition design surface 10: Pseudo fin part 11: Printing surface 12: Concave part 13: Convex part 15 : Printing surface 16: Deposition design surface 17: Film 18: Pseudo fin part 20: Mask material 21: First molding die 22: Second molding die 23: Mold surface of second molding die 25: Transparent resin layer 26: Radio wave transmission cover 27: Decorating body layer 28: Film existing surface 29: First molded body 30: Base material layer 31: Third molding die 33: Film 34: Printing surface 35: Deposition design surface 37: Adhesive Layer 38: Transfer surface 40: Printing surface 41: Transparent resin layer 42: Base material layer 43: First molded body 45: First molding die 46: Mold surface of first molding die 45 47: Second molding die 48: Third mold 50: Mold surface of third mold 48 51: Radio wave Overcover 52: Printing surface 53: Film 55: Deposition design surface 56: Bright piece 57: Adhesive layer 58: Transparent resin layer 61: First molded body 60: Film 62: Second molding die 63: Transparent resin layer 64 : 1st shaping | molding die 66: Design surface 67: Evaporation design surface 70: Transfer surface 71: 1st molded object 72: Decorating body layer 73: Film 75: 1st cover film layer 76: 2nd cover film layer 78: Second mold 82: Parting part 83: Deposition design surface 85: Printing surface 86: Colorless surface 87: Boundary part

Claims (13)

A method of manufacturing a resin radio wave transmission cover that is attached to an opening of a vehicle exterior member and has a radio wave radar device disposed on the back side,
A film forming process for forming a film having a predetermined design;
A shaping step of shaping the film into a predetermined shape;
The shaped film is placed in a mold, and one of the transparent resin layer and the base material layer is formed on the surface of the film on which the design is formed, and the film is removed to transfer the design. A first molding step of forming a first molded body having a transferred surface,
And a second molding step of molding the other of the transparent resin layer and the base material layer on the transfer surface of the first molded body. A method of manufacturing a resin radio wave transmission cover that is attached to an opening of a vehicle exterior member and has a radio wave radar device disposed on the back side,
Film forming step for forming a film having a predetermined design, one of a transparent resin layer and a base material layer is molded, and the film is formed on the one of the transparent resin layer and the base material layer disposed in a mold And forming the first molded body having a transfer surface onto which the design has been transferred by removing the formed film while facing the surface on which the design is formed to face each other. Forming process;
A method of manufacturing a radio wave transmission cover, comprising: a second molding step of molding the other of the transparent resin layer and the base material layer on the transfer surface of the first molded body. A method of manufacturing a resin radio wave transmission cover that is attached to an opening of a vehicle exterior member and has a radio wave radar device disposed on the back side,
Film forming step for forming a film having a predetermined design, one of a transparent resin layer and a base material layer is molded, and the film is formed on the one of the transparent resin layer and the base material layer disposed in a mold Forming step to form the first molded body by laminating and shaping into a predetermined shape,
A method of manufacturing a radio wave transmission cover, comprising: a second molding step of molding the other of the transparent resin layer and the base material layer on a film existing surface of the first molded body.   The radio wave transmission according to any one of claims 1 to 3, wherein the film has at least one of a printing surface having a predetermined design and a vapor deposition design surface on which a metal material whose crystal extends in the vapor deposition direction is vapor-deposited. Manufacturing method of the cover.   The method of manufacturing a radio wave transmission cover according to claim 4, wherein the film includes a bright piece having the vapor deposition design surface. The film has a film body having a printing surface having a predetermined design, and a bright piece having a vapor deposition design surface on which a metal material whose crystal extends in the vapor deposition direction is vapor-deposited,
In the film forming step, the film body and the glitter piece are formed,
In the shaping step, the film body is shaped into a predetermined shape,
In the first molding step, the first molded body is formed by molding one of the transparent resin layer and the base material layer in a state where the shaped film body and the bright piece are arranged in a mold. The method for manufacturing a radio wave transmission cover according to claim 1, wherein: The method for manufacturing a radio wave transmission cover according to any one of claims 4 to 6, wherein the metal material whose crystal extends in the vapor deposition direction is a metal material selected from indium, tin, and gold. The method of manufacturing a radio wave transmission cover according to claim 2 or 3, wherein, in the forming step, the transparent resin layer or the base material layer is formed and a design surface having a predetermined design is formed on the surface. In the film forming step, both surfaces of the film are covered with the first cover film layer and the second cover film layer, and at least the transparent resin layer of the first cover film layer or the second cover film layer. The method for manufacturing a radio wave transmission cover according to claim 1, wherein the side layer is formed of a transparent resin. In the film forming step, both sides of the glitter piece are covered with a first cover film layer and a second cover film layer, and at least the transparent resin of the first cover film layer or the second cover film layer The method for manufacturing a radio wave transmission cover according to claim 5, wherein the layer on the layer side is formed of a transparent resin. In the film forming step, at least one surface of the film main body and the bright piece is covered with a first cover film layer and a second cover film layer, and at least the first cover film layer or the second cover film layer. The method for producing a radio wave transmission cover according to claim 6, wherein a layer on the transparent resin layer side of the cover film layer is formed of a transparent resin. The method of manufacturing a radio wave transmission cover according to any one of claims 1 to 11, wherein in the shaping step or the shaping step, the shaping of the film is performed by vacuum forming or pressure forming. The one of the molds used in the first molding step or the forming step is also used in the second molding step, and the transparent resin layer and the base material layer are formed by two-color molding. A method for manufacturing a radio wave transmission cover according to any one of the above.

Images