Radio-wave-penetrable layer having metallic luster
10107894 ยท 2018-10-23
Assignee
Inventors
Cpc classification
H01Q1/3233
ELECTRICITY
G01S13/88
PHYSICS
H01Q1/42
ELECTRICITY
B60R19/52
PERFORMING OPERATIONS; TRANSPORTING
C23C14/086
CHEMISTRY; METALLURGY
C23C14/022
CHEMISTRY; METALLURGY
G02B5/0816
PHYSICS
International classification
B60R19/52
PERFORMING OPERATIONS; TRANSPORTING
C23C14/00
CHEMISTRY; METALLURGY
H01Q1/42
ELECTRICITY
Abstract
Disclosed is a coating layer penetrable by radio wave and having a metallic luster. The coating layer includes a resin layer as an outmost layer to an exterior or front, a metallic texture layer formed on a rear side of the resin layer and comprising a optical film layer including metal oxides having different refractive indexes, and a germanium (Ge) layer to reflect light and a reflection layer formed on the rear side of the metallic texture layer.
Claims
1. A coating layer for a vehicle part, comprising: a resin layer having a front side exposed to an outside and a rear side opposite to the front side; a metallic texture layer formed on the rear side of the resin layer, wherein the metal texture layer comprises i) an optical film layer comprising metal oxides having different refractive indexes and ii) a germanium (Ge) layer configured to reflect light; and a reflection layer formed on a rear side of the metallic texture layer.
2. The coating layer of claim 1, wherein the resin layer is transparent and the reflection layer is opaque.
3. The coating layer of claim 1, wherein the optical film layer comprises a first refractive layer comprising any one of TiO.sub.2 or Cr.sub.2O.sub.3 and a second refractive layer comprising SiO.sub.2.
4. The coating layer of claim 1, wherein in the optical film layer, the first refractive layer and the second refractive layer are alternately layered, and the first refractive layer is disposed closer to the resin layer than the second refractive layer.
5. The coating layer of claim 1, wherein the metallic texture layer has a reflectance of about 30% or greater and a reflectance deviation of about 5% P or less in a visible ray region of a wavelength of about 400 to about 700 nm.
6. The coating layer of claim 3, wherein each of the first refractive layer and the second refractive layer has a thickness of about 10 to 200 nm.
7. The coating layer of claim 3, wherein the optical film layer comprises three or more layers comprising the first refractive layers and the second refractive layers and has a total thickness of about 300 nm to about 10 m.
8. The coating layer of claim 4, wherein the germanium layer is formed on a front side of the optical film layer, on a rear side of the optical film layer, or between the alternately layered first refractive layer and the second refractive layer.
9. The coating layer of claim 8, wherein the germanium layer has a total thickness of about 50 nm to 5 m.
10. The coating layer of claim 1, wherein the front side of the resin layer has a flat or curved front surface having no concavo-convex portion, and the rear side has a surface having a concave portion and a convex portion.
11. The coating layer of claim 1, further comprising: a primer layer formed between the resin layer and the metallic texture layer.
12. The coating layer of claim 1, further comprising: a masking layer formed between the resin layer and the metallic texture layer, the masking layer covering at least a portion of the metallic texture layer, wherein the masking layer comprises an opaque paint to cover a remaining portion other than a portion having a predetermined shape.
13. A vehicle part comprising a coating layer of claim 1.
14. The vehicle part of claim 13 is a front grill of a vehicle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
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DETAILED DESCRIPTION
(9) The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.
(10) Unless specifically stated or obvious from context, as used herein, the term about is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. About can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from the context, all numerical values provided herein are modified by the term about.
(11) It is understood that the term vehicle or vehicular or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle that has two or more sources of power, for example both gasoline-powered and electric-powered vehicles.
(12) Unless defined otherwise, all the terms used in this specification, including technical and scientific terms, have the same meanings as would be generally understood by those skilled in the related art. The terms defined in generally used dictionaries should be construed as having the same meanings as would be construed in the context of the related art, and unless clearly defined otherwise in this specification, should not be construed as having idealistic or overly formal meanings.
(13) Hereinafter, a coating layer that may be penetrable by radio wave and have a metallic luster according to preferred embodiments of the present invention will be described with reference to the accompanying drawings.
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(15) The resin layer 10 may be transparent, for example, by including transparent plastics, for example, polycarbonate and acryl resins, and may constitute the outermost portion of the coating layer according to the present invention. For instance, the resin layer 10 may be a front surface of a front grill of a vehicle. Preferably, the resin layer 10 may be transparent. Accordingly, external light may be transmitted to the metallic texture layer 100a while the metallic texture layer 100a is protected, or light that is reflected on the metallic texture layer 100a to exhibit a metallic texture may be transmitted through the resin layer to the outside.
(16) The resin layer 10 suitably may have an even flat or curved front side and an uneven rear side having a concavo-convex portion. For instance, the uneven rear side continuously may extend from a surrounding radiator grill or the emblem or object symbolizing the vehicle maker.
(17) When the metallic texture layer 100a is formed on the uneven rear side of the resin layer 10, a steric metallic texture reflected light section having a desired shape may be obtained.
(18) The metallic texture layer 100a may comprise an optical film layer 30a and a germanium layer 40a. In the optical film layer 30a, metal oxides such as ceramics, having different refractive indexes may be alternately layered. The germanium layer 40a may be a layer including germanium (Ge), which is a semiconductor.
(19) The metallic texture layer 100a may suitably reflect light to thus exhibit a metallic texture and may have electric conductivity less than that of a convention metallic material. Accordingly, the metallic texture layer 100a may have increased or substantially increased radio-wave penetrability.
(20) Preferably, in the metallic texture layer 100a, the multilayered optical film layer 30a may include a first refractive layer including a material having greater refractive index, for example, TiO.sub.2 or Cr.sub.2O.sub.3, and a second refractive layer including a material having a less refractive index, for example, SiO.sub.2. Preferably, the first refractive layer and the second refractive layer may be alternately layered therein. When the first refractive layer and the second refractive layer are alternately layered, constant reflectance may be maintained in a visible light band and achromatic reflected light may be obtained so as to exhibit a metallic texture.
(21) Preferably, when the multilayered optical film layer 30a is formed, the first refractive layer including TiO.sub.2 may be disposed so as to be closest to the resin layer 10 or at least closer to the resin layer than the second refractive resin layer. This may be because the adhesion strength of TiO.sub.2 is greater than that of other materials. When TiO.sub.2 is first layered on the resin layer 10, the possibility of stripping between the resin layer 10 and the multilayered optical film layer 30a may be reduced. The second refractive layer comprising SiO.sub.2 having greater hardness may improve scratch resistance of the multilayered optical film layer 30a. In addition, SiO.sub.2 included in the second refractive layer may implement the reflected light, which is the characteristic of the metal.
(22) The thicknesses of the first and second refractive layers of the multilayered optical film layer 30a may be controlled to fall within the range from about 10 to about 200 nm, the total thickness thereof may be controlled to fall within the range from about 300 nm to about 10 m. Moreover, three or more layers of the first and second refractive layers may be included in the optical film layer, thereby minimizing differentiation of colors depending on the reflection angle and reflecting light that exhibits a metallic texture.
(23) The germanium layer 40a may be disposed so as to reflect light exhibiting a further distinct metallic texture on the multilayered optical film layer 30a. Since germanium exhibits a dark-colored metallic texture due to the intrinsic characteristics thereof, the metallic texture layer 100a including the multilayered optical film layer 30a and the germanium layer 40a may reflect light exhibiting a chrome-colored metallic texture that is slightly darker than that of typical chrome-reflected light. The dark chrome color may improve the appearance of parts.
(24) When the thickness of the germanium layer 40a is about 10 m or greater, the penetrability of the radio waves of the radar may be substantially reduced. Accordingly, the thickness of the germanium layer 40 may be about 5 m or less so as to prevent the radio-wave penetrability from being reduced. On the other hand, when the thickness of the germanium layer 40a is less than about 50 nm, light reflection exhibiting a further distinct metallic texture on the multilayered optical film layer 30a may not be obtained. Therefore, the thickness of the germanium layer 40a must fall within the range from about 50 nm to about 5 m.
(25) The germanium layer 40a may be formed on the rear side of the multilayered optical film layer 30a, that is, between the multilayered optical film layer 30a and the reflection layer 50, but may be formed at another position in another embodiment of the present invention. A description thereof will be given below.
(26) Light may be reflected to thus exhibit a metallic texture without exhibiting different colors (a phenomenon whereby only a specific color is noticeable). Preferably, the total visible ray reflectance of the metallic texture layer 100a including the multilayered optical film layer 30a and the germanium layer 40a may be about 30% or greater and the reflectance deviation in a visible ray region may be about 5% P or less.
(27) Preferably, the rear side of the resin layer 10 may be uneven and the metallic texture layer 100a may be formed on the uneven rear side. Since the sensation of different colors is easily caused by the reflectance deviation on the sterically uneven side compared to the flat side, light may be reflected on the uneven rear side of the resin layer 10 and may exhibit an achromatic, without color, metallic texture only when the reflectance and deviation limits set forth in the present invention are satisfied.
(28) The reflection layer 50 may be formed on the rear side of the metallic texture layer 100a using opaque paint, preferably black paint. The reflection layer may improve the reflectance of the metallic texture layer 100a, thereby increasing the brightness of the reflected light.
(29) After the metallic texture layer 100a is formed, the reflection layer 50 may be formed on the rear side of the metallic texture layer, thereby increasing the brightness of the light reflected on the metallic texture layer 100a to thus exhibit the metallic texture and ensuring environmental and scratch resistance.
(30) The coating layer of the present invention may further include a primer layer 20 between the resin layer 10 and the metallic texture layer 100a. The primer layer 20 may provide a gloss or matte effect to the light, reflected on the metallic texture layer 100a to exhibit the metallic texture, thereby improving the appearance of the coating layer.
(31) The coating layer of the present invention may further include a masking layer comprising opaque paint, preferably black paint, between the resin layer 10 and the multilayered optical film layer 30a.
(32) The masking layer may cover at least a portion of the multilayered optical film layer 30a to thus define a section of the multilayered optical film layer on which the light is reflected to exhibit the metallic texture, thereby providing a predetermined structure or a pattern. The structure may be a pattern or design for a radiator grill, an emblem, or a symbol. The uneven rear side of the resin layer 10 and the masking layer may be combined to ensure the steric section, on which the light is reflected to exhibit the metallic texture.
(33) The masking layer may define the section of the multilayered optical film layer on which the light is reflected to exhibit the metallic texture in the embodiment of the present invention. However, the present invention is not limited thereto, and the section embodying the metallic texture may be defined using various processes for etching the metallic texture layer 100a.
(34) The structure or pattern of the metallic texture layer according to the present invention is not limited to one Example shown in
(35) For instance, as shown in
(36) When the germanium layer 40c is formed between the multilayered optical film layers 30c, it is preferable that the germanium layer 40c be formed between the first refractive layer and the second refractive layer of the multilayered optical film layers 30c.
(37) The method for forming the metallic texture layers 100a, 100b, and 100c is not particularly limited in the present invention. However, for example, the metallic texture layers may be deposited on the resin layer 10 using a PVD or PACVD process, or the resin layer 10 may be subjected to sputtering.
(38) For instance, Ar gas may be converted into a plasma in a vacuum state, and a bias may be applied to wash and activate the surface of the resin layer 10, particularly the rear side of the resin layer, thereby increasing the stickiness between a mother material and the deposited layer. An e-beam may be radiated on the samples of the high refractive material (TiO.sub.2 and/or Cr.sub.2O.sub.3) and the low refractive material (SiO.sub.2) to form the multilayered optical film layer 30a on the surface of the resin layer, or the e-beam may be radiated on the germanium (Ge) sample to form the germanium layer 40a.
(39) Hereinafter, the effects of the Examples of the present invention will be described.
(40) A conventional radiator grill for use in vehicle exteriors is plated with chrome. Therefore, reflectance similar to that of chrome may be required in order to realize a metallic texture similar to that of the radiator grill. A change in the reflectance of typical chrome, a change in the reflectance of a tin-deposited layer of the related art, and a change in the reflectance of the metallic texture layer 100a including the multilayered optical film layer 30a and the germanium layer 40a of an exemplary coating layer according to the present invention in a visible light region (a wavelength of 400 to 700 nm) were numerically calculated using a Macleod analytic program, and the calculated values are described in Table 1.
(41) In Table 1, Comparative Examples 1 to 5 were samples where the monolayer of each material was formed on the resin layer. Examples 1 to 4 are samples where the resin layer 10, the primer layer 20, the multilayered optical film layer 30a, the germanium layer 40a, and the opaque reflection layer 50 are sequentially formed as in
(42) TABLE-US-00001 TABLE 1 Thickness Number Visible ray (wavelength of 400 to 700 nm) reflectance % Material (nm) of layers 400 450 500 550 600 650 700 Max Min Comparative Cr 20 Monolayer 33.23 35.21 36.34 36.2 34.05 31.97 31.46 4.88 Example 1 Comparative 30 40.17 42.32 43.26 43.25 42.03 40.79 39.82 3.44 Example 2 Comparative 100 41.41 43.44 43.3 42.21 41.82 42.48 43.36 2.03 Example 3 Comparative Sn 100 27.98 27.9 28.63 29.55 29.83 29.25 28.05 1.93 Example 4 Comparative Ge 50~10000 Monolayer 26.25 23.8 21.36 21.44 22.8 21.73 26.63 4.89 Example 5 Example 1 Ge + 306 3 34.37 33.21 31.94 31.34 31.61 31.79 32.46 3.03 Example 2 Multilayered 526.3 7 42.56 45.52 44.01 46.05 47.05 45.22 41.7 0.28 Example 3 optical 674 11 50.29 52.77 50.11 52.6 54.48 52.3 46.26 4.38 Example 4 film 1,549 15 56 63.8 63.39 63.2 63.32 61.94 62.03 2.28
(43) As shown in Table 1, the reflectance was 30% or greater in the entire visible ray region and that the max-min deviation of the reflectance is 5% P or less based on the reflectance of chrome of Comparative Examples 1 to 3 in Table 1. This means that the brightness must be a predetermined value or greater, e.g. 30% or greater, and that the reflectance may be required to be uniform throughout the entire visible ray region in order to realize a chrome texture.
(44) In addition, tin of Comparative Example 4 had low reflectance deviation, light was reflected on tin to exhibit an achromatic metallic texture, but the brightness was reduced due to the total reflectance of less than about 30%. Further, germanium of Comparative Example 5 had low reflectance due to its intrinsic dark color.
(45) On the other hand, Examples 1 to 4 having the total thickness of the multilayered optical film layers 30a of about 300 nm or greater and including layers of 3 or greater satisfied the condition that the reflectance was 30% or greater and the reflectance deviation was 5% P or less in the visible light region. As the number of multilayered optical film layers 30a was increased, the reflectance in the visible ray region was increased, which increase the brightness of the reflected light, and the reflectance deviation is 5% P or less in all Examples. Accordingly, a metallic texture may be exhibited without differentiation in colors when the light is reflected.
(46)
(47) Meanwhile, as shown in
(48) The sample of the metallic texture layer 100a according to the present invention and the conventional indium-coated sample were manufactured, and the damping ratio and the straightness of the radio waves of the radar were measured with respect to the samples. The result is described in Table 2.
(49) An exemplary coating layer was deposited on a plate, which had a thickness of 1 mm and included a PC material, to thus manufacture each sample. Indium (In) was deposited in Comparative Example 6. In Examples 5 to 7, the germanium layer 40a and the multilayered optical film layer 30a were included, and the respective numbers of multilayered optical film layers 30a was 3, 7, and 15.
(50) TABLE-US-00002 TABLE 2 Damping Radar Radar Number ratio of beam tilt beam tilt of radar [X-axis [Y-axis Material layers [dB] degree] degree] Comparative In Mono- 0.66 0.04 0.06 Example 6 layer Example 5 Ge + Multi- 3 0.66 0.02 0.04 Example 6 layered 7 0.66 0.02 0.04 Example 7 optical film 15 0.66 0.02 0.04
(51) the damping ratio and the refraction angle were measured at a frequency of the radio wave of the radar of 76 to 77 GHz using a RAS (radar alignment system) measuring device.
(52) As shown in Table 2, the radio-wave penetrability of the sample of the metallic texture layer 100a according to Examples 5 to 7 was the same as the radio-wave penetrability of the indium-coated sample according to Comparative Example 6 regardless of the number of multilayered optical film layers 30a, and that the straightness of the radar beam was the same as or greater than that of the sample of Comparative Example 6.
(53) Preferably, a damping ratio of the radar suitable for the coating layer according to the present invention may be about 4 dB or less (4 to 0 dB) on the basis of round-trip penetration and about 1.8 dB or less (1.8 to 0 dB) on the basis of one-way penetration.
(54) TABLE-US-00003 TABLE 3 Thickness of Number of germanium multilayered layer optical film Visible ray (wavelength of 400 to 700 nm) reflectance (%) Classification (nm) layers 400 450 500 550 600 650 700 Max Min Example 8 406 5 43.56 43.52 42.01 44.35 44.02 43.22 40.1 4.25 (FIG. 2) Example 9 400 5 40.02 42.9 41.82 40.9 40 39.7 38.8 3.1 (FIG. 3) Example 10 408 5 41.56 41.22 39.01 41.05 40.65 40.22 38.76 2.8 (FIG. 4)
(55) The cover samples comprising the coating layers of the Examples of
(56) During analysis, the numbers of multilayered optical film layers 30a, 30b, and 30c were maintained the same, (i.e. 5 layers), in the samples, but the germanium layers 40a, 40b, and 40c were positioned on different sides, that is, on the rear side of the multilayered optical film layer (on the opaque reflection layer), on the front side of the multilayered optical film layer (on the resin layer), and between the multilayered optical film layers (between the first and second refractive layers).
(57) As a result, the reflectance of the metallic texture layer 100b including the multilayered optical film layer 30b and the germanium layer 40b, formed on the rear side of the multilayered optical film layer 30b, that is, the reflectance of Example 8, was greatest. However, the reflectances of all samples were 38 to 44%, greater than at least 30%, in the visible light wavelength region. Further, the reflectance deviations of all samples were 5% P or less in the visible ray region. Accordingly, an achromatic metallic texture may be exhibited when light is reflected.
(58) TABLE-US-00004 TABLE 4 Damping Radar Radar ratio of beam tilt beam tilt radar [X-axis [Y-axis Classification [dB] degree] degree] Example 8 (FIG. 2) 1.65 0.12 0.07 Example 9 (FIG. 3) 1.5 0.13 0.07 Example 10 (FIG. 4) 1.47 0.13 0.08
(59) The damping ratio and the straightness of the samples having the measured reflectance of Table 3 were evaluated using an RAS measuring device during one-way penetration of radio waves having a frequency of 76 to 77 GHz and a wavelength of 400000 nm. The results are described in Table 4.
(60) As shown in
(61) The sample of the metallic texture layer 100a according to the present invention and the indium- and germanium-coated samples were manufactured, and the high-temperature durability of the samples was examined. The results are shown in
(62) A target structure was deposited on a glass substrate to manufacture each sample. Indium, germanium, and the multilayered optical film layer 30a with the germanium layer 40a were deposited in Comparative Example 7, Comparative Example 8, and Example 11, respectively. Subsequently, in order to measure environmental resistance at high temperatures, the respective samples were heat-treated at a temperature of 220 C. for 5 min to confirm the degree of deformation of the deposition surface. Deformation was confirmed from the many cracks formed in the surface in Comparative Example 7, but no cracks were formed in the surface in Comparative Example 8 or in Example 11.
(63) TABLE-US-00005 TABLE 5 Applied material In Ge TiO.sub.2 SiO.sub.2 Melting point ( C.) 156 939 1,670 1,975
(64) As shown in
(65) Thermal deformation, such as surface cracks, did not occur in Comparative Example 8, using only germanium, but the sample of Comparative Example 8 had a color that was darker than that of Example 11. This is because the brightness of the reflected light may be reduced due to the low reflectance of germanium, as in Comparative Example 5 of Table 1.
(66) Various exemplary embodiments of the present invention have been described with reference to the accompanying drawings, but those skilled in the art will appreciate that the present invention may be embodied in other specific forms without changing the technical spirit or essential features.
(67) Thus, exemplary and preferred embodiments described above should be understood to be illustrative in every way and non-limiting. The scope of the invention is represented by the claims below rather than the aforementioned detailed description, and all of the changes or modified forms that are derived from the meaning, range, and equivalent concepts of the appended claims should be construed to be included in the scope of the present invention.