Multi-layered articles or products comprising layers of filled polymer compositions, methods of making and applications or uses thereof.

A process for manufacturing a composite material of 3-D shape, includes a stack of layers of resin and fibre, incorporating at least one metal layer, the process comprising the following steps, a standard unit pattern having been determined for the metal layer: i/computing periodically organized patterns on the 3-D shape, which is non-developable; then projecting, onto a plane, the patterns, thus defining a planar organization of second patterns; ii/partially polymerizing, flat, first layers, comprising a metal top layer, of the flat composite stack, so as to make it etchable, but to keep it still deformable; iii/electrochemically etching the organization of second patterns that was defined in step i into the metal top layer of the flat composite stack resulting from step iv/carrying out polymerization of the etched composite stack after the stack has been placed in a mould having the desired 3-D shape.

Low-density thermoplastic expandable microspheres are disclosed. Various low-density structures, in particular, sandwich panels, based on foam prepared from the low-density microspheres, are also disclosed. Process of preparing low-density polymeric microspheres, per se, and the corresponding low-density structures, based on the microsphere foam, are also disclosed.

A low profile phased array antenna that is configured to be manufactured using additive manufacturing techniques is provided. In one or more embodiments, the phased array can include a plurality of signal ears, ground ears, and clustered pillars that can be arranged in relation to a base plate such that each component of the antenna can be manufactured from a single piece of material, thereby allowing for the use of additive manufacturing techniques which can substantially reduce the cost and time of the manufacturing process. The phased array can include a signal ear that include one or more posts that interface with an airgap located within a base plate of the array, wherein the size of the airgap in relation to the size of the post is configured to achieve an optimal level of impedance matching.

An example antenna device may includes a base member, an antenna that is attached to the base member, and a cover member that is attached to surround at least a part of the base member and at least a part of the antenna. A first part of the base member that is attached to the cover member has a melting temperature equal to or lower than that of the cover member. A second part of the base member to which the antenna is attached has a higher melting temperature than the cover member.

A method for manufacturing a radar cover which covers a radar unit configured to detect surrounding conditions of a vehicle includes: preparing a base having a recessed portion formed of a transparent layer and comprising a colored layer stacked on a portion other than the recessed portion, and a shining member comprising a basal portion including a shining layer on a surface thereof and an edge portion; arranging the base and the shining member such that the edge portion of the shining member and the colored layer of the base are in contact with each other and the shining layer of the basal portion and the recessed portion face each other; and fixing the edge portion and the colored layer to each other.

A radome for an antenna is provided as a composite of an isotropic outer layer and a structural layer of foamed polymer material. The composite is dimensioned to enclose an open end of the antenna. The radome may be retained upon the antenna by a retaining element and fasteners. The outer layer may be a polymer material with a water resistant characteristic. The structural layer may project inward and/or outward with respect to a plane of the seating surface of the radome.

Method and apparatus for making antennas and antenna components suitable for wideband transmission and reception are disclosed. Material accretion devices or apparatus such as a 3D printer can be used to form the antennas and antenna components. The antenna and antenna components can include folded and/or self-similar features.

A first resin layer (1) has: a covered region which is covered by a second resin layer (2) and an exposed region (1a); a contact part (1b) which is provided in the exposed region (1a); and a bend part (1c) which is provided between (a) a boundary between the covered region and the exposed region (1a) and (b) the contact part (1b).

A radome for housing a radar system comprises a plurality of interconnected curved radome thermoplastic composite material panels, each curved radome thermoplastic composite material panel having a plurality of interconnecting edges, a foam core, an inner skin, an outer skin, and a plurality of three-dimensional fiber bundles tying the inner skin and the outer skin to each other through the foam core, inhibiting delamination. The radome includes a hydrophobic exterior surface that is self-cleaning and requires zero maintenance for 25 years.