Radome illuminated grille
Trim components, such as automotive radomes and automotive grille assemblies, and their methods of manufacture include a polycarbonate (PC) member defining a radar-transmissive radar zone and a multi-layer stack arranged on both a front or A-side of the PC member and a back or B-side of the PC member such that the PC member is therebetween, the multi-layer stack including a plurality of layers configured to provide protection of the front or A-side of the PC member, provide a visible decoration on the back or B-side of the PC member, provide a heater assembly configured to selectively heat the radar zone, and provide leveling in the radar zone. At least some of the plurality of layers, such as the PC member or a heating assembly layer, could be light diffusive.
1 . A trim component, comprising:
a polycarbonate (PC) member defining a radar-transmissive radar zone; and
a multi-layer stack comprising a plurality of layers, at least one of the plurality of layers being arranged on both a front or A-side of the PC member and a back or B-side of the PC member such that the PC member is therebetween, one or more of the plurality of layers being configured to:
(a) provide protection of the front or A-side of the PC member;
(b) provide a visible decoration on the back or B-side of the PC member; and
(c) provide leveling in the radar zone, wherein the leveling comprises a leveling material filling air gaps between the lens member and the PC member to provide a uniform thickness for optimal radar transmission performance.
2 . The trim component of claim 1 , wherein the plurality of layers further provide a heater assembly configured to selectively heat the radar zone.
3 . The trim component of claim 1 , wherein at least one of the plurality of layers of the multi-layer stack is light diffusive.
4 . The trim component of claim 3 , wherein at least one of the plurality of layers of the multi-layer stack is a lens member arranged on the back or B-side of the PC member.
5 . The trim component of claim 4 , wherein the lens member is further configured as a lightguide to direct and emit light within the radar zone and through a remainder of the multi-layer stack.
6 . The trim component of claim 1 , wherein the multi-layer stack comprises a multi-layer opaque decorative film layer disposed on the back or B-side of the PC member and comprising a heater assembly layer and a leveling material layer in the radar zone.
7 . The trim component of claim 6 , wherein the multi-layer stack further comprises a polyurethane reactive (PUR) lamination layer disposed on a front or A-side of the PC member.
8 . The trim component of claim 1 , wherein the multi-layer stack comprises:
a front protective layer disposed on the front or A-side of the PC member;
a pad print decorative layer disposed on the back or B-side of the PC member;
a physical vapor deposition (PVD) decorative layer disposed on the back or B-side of the PC member; and
a heater assembly integrated with the leveling material layer applied to the back or B-side of the PC member in the radar zone.
9 . The trim component of claim 1 , wherein the multi-layer stack comprises:
a front protective layer disposed on the front or A-side of the PC member;
a laser ablated paint decorative layer disposed on a back or B-side of the PC member;
a physical vapor deposition (PVD) decorative layer disposed on the back or B-side of the PC member; and
a heater assembly integrated with the leveling material layer applied to the back or B-side of the PC member in the radar zone.
10 . The trim component of claim 1 , wherein the heating assembly layer is light diffusive.
11 . The trim component of claim 1 , wherein the PC member is formed of a light diffusive grade of PC such that it is light diffusive.
12 . The trim component of claim 1 , wherein the plurality of layers of the multi-layer stack further comprises a light diffusive film or finish layer applied to at least one of the front or A-side and the back or B-side of the PC member.
13 . The trim component of claim 1 , wherein the trim component is an automotive radome.
14 . The trim component of claim 1 , wherein the trim component is an automotive grille assembly.
15 . A method of forming the trim component of claim 1 , the method comprising the step of positioning the multi-layer stack adjacent the polycarbonate (PC) member defining the radar-transmissive radar zone.
16 . The method of claim 15 , wherein the PC member is formed by injection molding.
17 . The method of claim 16 , wherein the injection molding is a multi-shot injection molding process.
18 . The method of claim 15 , wherein the method further comprises physical vapor deposition (PVD).
19 . The method of claim 15 , wherein the method further comprises film deposition.
20 . The method of claim 15 , wherein the process is iterative.