Method for producing a layered structure in a multi-component process

Abstract

A method for producing a layered structure in a multi-component process includes the steps of: generating a basic substrate composed of a transparent plastic, in particular of polycarbonate, in a first manufacturing step, and coating the basic substrate with a transparent resin layer, in particular composed of polyurethane, in a second manufacturing step.

Claims

1. A method for producing a layered structure in a multi-component process, wherein the layered structure is a radome of a self-driven vehicle, comprising: generating a basic substrate composed of a transparent plastic, in a first manufacturing step; coating the basic substrate with a transparent resin layer, in a second manufacturing step; and selecting a wall thickness of the basic substrate in conjunction with the transparent resin layer such that the wall thickness constitutes a multiple of a wavelength in the material of the basic substrate for a radar frequency range, wherein the transparent resin layer has a radar transparency which is identical to a radar transparency of the basic substrate, wherein a transparent heating film is integrated between the basic substrate and the resin layer and wherein the heating film is applied to a surface of the basic substrate prior to the coating operation of the basic substrate and is subsequently covered over its entire area with the resin layer in a flooding process, the heating film being located so as to be completely embedded between the resin layer and the basic substrate after the coating operation.

2. The method according to claim 1, wherein the transparent plastic is polycarbonate, and the transparent resin layer is composed of polyurethane.

3. The method according to claim 1, wherein after the basic substrate has been generated, the basic substrate remains in a production tool, and the coating of the basic substrate takes place while the basic substrate is located in the production tool.

4. The method according to claim 1, wherein a lacquer layer is applied directly to a surface of the basic substrate, said surface facing away from the resin layer.

5. The method according to claim 4, wherein the lacquer layer is initially applied over the entire area of that surface of the basic substrate which faces away from the resin layer, and is subsequently removed, at least in certain portions, by way of laser ablation or by way of mechanical machining.

6. The method according to claim 4, wherein, before the lacquer layer is applied, a mask is applied to at least certain portions of a surface of the basic substrate, said surface facing away from the resin layer, and the lacquer layer is applied to the mask in masked regions and is applied directly to the surface of the basic substrate in non-masked regions.

7. The method according to claim 4, wherein the lacquer layer is applied at least to a side of the basic substrate, said side facing away from the resin layer, by way of a printing method, and the lacquer layer is applied to only certain portions of the surface of the basic substrate, whereby regions with the lacquer layer and regions without the lacquer layer are produced on said surface.

8. The method according to claim 4, wherein after the lacquer layer has been applied, a transparent adhesion-promoter layer is applied to the lacquer layer in a layer thickness of 5 μm to 50 μm.

9. The method according to claim 8, wherein a decorative layer composed of a semiconductor is applied to the transparent adhesion-promoter layer by physical vapor deposition.

10. The method according to claim 9, wherein a non-transparent topcoat is applied to the decorative layer by a spraying method.

11. The method according to claim 1, wherein end-side surfaces of the basic substrate, which basic structure is provided with one or more layers, including the basic substrate, are sealed with a resin.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) FIG. 1 shows a section through a layered structure according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWING

(2) FIG. 1 shows a sectional view through a layered structure 10 which was produced in a multi-component process and which is used as a radome. The radome 10 can be used as an external cladding part of a vehicle and conceals a radar sensor 20 which is arranged in the interior of the vehicle. The radar sensor 20, which is arranged behind the radome 10, is not visible from an outer side of the vehicle.

(3) The radome 10 has a basic substrate 11. A resin layer 17 is applied to a surface of the basic substrate 11, said surface facing away from the radar sensor 20. A heating film 16 is arranged at least in certain portions between the resin layer 17 and the basic substrate 11. The heating film 16 can be used to control the temperature, in particular heat, of the outer surface of the resin layer 17, and thus of the radome 10, in order to remove precipitation such as rainwater, ice or snow. Furthermore, the heating film can be actuated such that, in the resin layer 17, a temperature is induced at which a self-healing process is triggered, by way of which damage in the surface of the resin layer, such as scratches or pores, is closed.

(4) A lacquer layer 12 is applied to the rear side of the substrate 11, that is to say to a surface of the substrate 11 that faces toward the radar sensor 20. This lacquer layer has apertures or cutouts 19, 19′ which are arranged in the form of a pattern. By means of the lacquer layer 12, it is possible to generate an outwardly visible coloring of the radome. An adhesion-promoter layer 13 is applied to the surface of the lacquer layer 12, said surface facing away from the basic substrate 11. A decorative layer 14 is applied to the adhesion-promoter layer, said decorative layer being visible from an outer side of the vehicle or from an outer side of the radome 10 through the cutouts 19, 19′ in the lacquer layer 12. A two-colored effect of the radome 10 can thus be generated. A final layer 15 composed of a non-transparent topcoat is applied to a side of the decorative layer 14, said side facing toward the radar sensor 20. The end sides of the layers and of the basic substrate can be sealed with a resin 18. The resin 18 preferably completely surrounds the radome 10 or the basic substrate 11 and all of the layers 12, 13, 14, 15 and 17 in a circumferential direction. In order to avoid stray light, the resin 18 can preferably be formed from black material.

(5) The functioning of the radome 10 will be briefly explained below. The radar sensor 20 emits radar waves in an emission direction E. These radar waves penetrate the radome 10 from a rear side, beginning with the non-transparent topcoat layer 15 and ending with the resin layer 17. After exiting the radome through the resin layer 17, the radar waves impinge on an object 30 that is located in front of the radome or in front of the vehicle. The radar waves are reflected on this object 30 and penetrate through the radome in a reflection direction R. They pass through the radome in the reverse direction, this time from the resin layer 17 to the topcoat 15. After exiting the radome 10 through the topcoat 15, said radar waves are captured again by the radar sensor 20.

(6) The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.