Patent Application
20240034886
The technical field relates generally to coatings, and more particularly to dielectric pigments having a metallic appearance for a radar compatible coating that, for example, can be applied onto a component substrate to provide an aesthetic appearance while being substantially transparent to radar, and methods for making such dielectric pigments.
Radar is used in motor vehicles to detect objects for a variety of purposes, such as autonomous driving, adaptive cruise control, blind spot detection, automatic braking, and other advanced driver assistance systems. The radar sensor is typically mounted behind a component of the motor vehicle, typically a bumper or vehicle panel, so the component covers the radar device. In this regard, the radar signal must penetrate the bumper when traveling to an object to be detected, and then penetrate the bumper again when reflected off of the object and returning to the vehicle. The bumper, including any coatings applied to the surface of the bumper, can transmit, reflect, or absorb radar. Any reflection or absorption of the radar signal limits the effective detection range of the radar. For the radar to be useful for automatic braking or other advanced or autonomous driving features, the effective range of the radar must be at least as far as the braking distance of the vehicle at the driving speed.
If the component, e.g., the bumper or vehicle panel, behind which the radar is mounted is metal, the effective range of the radar is zero, so the components utilized are typically plastic or other non-metallic materials. The component includes the substrate, but also typically includes a coating overlying the substrate. Motor vehicle coatings typically include a basecoat, and often also include a primer coat and/or a clearcoat, with an interface between each layer. The radar typically used in motor vehicles for detecting objects is 77 giga hertz (GHz) band radar, which describes a category of radar that includes frequencies from about 76 to 81 GHz (e.g., W Band).
The transmission of radar through a typical bumper substrate and the coating layers thereon is therefore important for the effective operation of many vehicle radar systems. Further, many vehicle exterior coating or paint systems include ingredients that provide an aesthetically desirable appearance. For example, many coating systems use special effect ingredients, such as metallic effect ingredients or the like, to enhance the aesthetic appearance of the paint. Unfortunately, some of these ingredients can confound a radar system's functionality when applied to a component substrate, such as, for example, a plastic bumper substrate or the like, because these ingredients are not radar compatible (e.g., not substantially transparent or transmissive to radar signals) as they substantially reflect and/or absorb radar signals, thereby limiting or blocking transmission of the radar through the component panel.
Accordingly, it is desirable to provide special effect ingredients for radar compatible coatings that, for example, can be applied onto a component substrate to provide an aesthetic appearance while being substantially transmissive to radar. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with this background.
Dielectric pigments having a metallic appearance for radar compatible coatings and methods for making such dielectric pigments are provided herein. In accordance with an exemplary embodiment, the dielectric pigment includes a flake. The flake includes a plurality of alternating layers of dielectric materials including a first layer formed of a first dielectric material having a first refractive index in the visible spectrum range and a second layer disposed adjacent to the first dielectric layer and formed of a second dielectric material having a second refractive index in the visible spectrum range that is different than the first refractive index.
In accordance with an exemplary embodiment, the method for making dielectric pigments having a metallic appearance for a radar compatible coating includes forming a plurality of alternating layers of dielectric materials overlying a substrate. Forming the plurality of alternating layers of dielectric material includes depositing a first layer of a first dielectric material overlying the substrate. The first dielectric material has a first refractive index in the visible spectrum range. A second layer of a second dielectric material is deposited overlying the first layer. The second dielectric material has a second refractive index in the visible spectrum range that is different than the first refractive index. The method further includes removing the substrate from the plurality of alternating layers of dielectric materials and breaking, crushing, and/or grinding the plurality of alternating layers into flakes to form the dielectric pigments.
In accordance with an exemplary embodiment, the radar compatible coating includes one or more resins. Dielectric pigments are incorporated into the one or more resins and having a metallic appearance. Each of the dielectric pigments includes a flake. The flake includes a plurality of alternating layers of dielectric materials including a first layer formed of a first dielectric material having a first refractive index in the visible spectrum range and a second layer disposed adjacent to the first dielectric layer and formed of a second dielectric material having a second refractive index in the visible spectrum range that is different than the first refractive index. Optionally, the radar compatible coating further includes one or more additives, one or more promoters, one or more curing agents, a water and/or solvent-based carrier, one or more colorants, one or more pigments, or combinations thereof.
The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
The following detailed description is merely exemplary in nature and is not intended to limit the various embodiments or the application and uses thereof. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
A vehicle “component,” as used herein, includes a plastic or polymeric substrate with an overlying coating. The term “overlying,” as used herein, means the overlying material may be physically touching the underlying substrate, or the overlying material may be physically separated from the underlying substrate by an intervening material, such as an overlying layer that may be separated from an underlying substrate by another layer. It is understood that a component may be rotated or moved, so reference to one component overlying another refers to a particular orientation, with the understanding that the actual component may be rotated into a different orientation. The term “vehicle,” as used herein, refers to a motor vehicle, such as a car, truck, airplane, or other device propelled through space with a motor or engine. The term vehicle includes vehicles propelled by a motor burning fuel for power, and a vehicle propelled by an engine using electricity. The overlying coating of the component includes one or more of a primer, a basecoat, and a clearcoat.
Various embodiments contemplated herein relate to dielectric pigments having a metallic appearance for a radar compatible coating that, for example, can be applied onto a component substrate to provide an aesthetic appearance while being substantially transmissive to radar. As used herein, the term “radar compatible” is understood to mean substantially transparent or transmissive to radar signals with relatively low (e.g., radar signal loss is less than about 20%, or 1 dB) or no transmission loss of the radar signal while traveling through the designated medium.
Referring to
In an exemplary embodiment, the radar compatible coating 10 is a paint or coating composition that is applied to the substrate 14 in an uncured or wet state and that is subsequently cured and/or dried. Paint formulation may be, for example, a primer formulation, a sealer formulation, a basecoat formulation, a clearcoat formulation, a topcoat formulation, and/or a tinted coat formulation. In an exemplary embodiment, the radar compatible coating 10 is a basecoat.
The radar compatible coating 10 includes a paint or resin matrix 16. Non-limiting examples of resins that may be present in the paint or resin matrix 16 include one or more types of resins, such as an acrylic resin, an epoxy resin, a polyurethane resin, and/or the like. In addition to the dielectric pigments 12 incorporated therein, the radar compatible coating 10 may include various other ingredients such as various additives, promoters, curing agents, a water and/or solvent-based carrier that flashes off during drying or curing of the paint formulation, colorants, and other pigments that may add special effect and/or color without significantly deteriorating the radar transparency or transmissivity of the coating 10.
In the uncured state, the radar compatible coating 10 may be sprayed or otherwise deposited onto the underlying substrate 14 using conventional techniques. For example, the radar compatible coating 10 may be deposited onto the underlying substrate 14 via an applicator, such as a spray gun, for example in a refinishing paint setting or alternatively, in an industrial painting setting. In another example, the applicator may be a printhead, for example in a refinishing paint setting or alternatively, in an industrial painting setting. In yet another example, the applicator may be a rotary bell applicator, for example in an industrial painting setting. Once cured and/or dried, the radar compatible coating 10 provides an aesthetic appearance, protection and/or improved durability to the underlying substrate 14 and is substantially transparent or transmissive to radar signals with relatively low radar signal loss.
In an exemplary embodiment, the dielectric pigments 12 include or are in the form of flakes 18 that have a highly reflective or metallic appearance in the visible spectrum range. As used herein, the “visible spectrum range” is understood to mean wavelengths of from about 400 about 700 nm.
In an exemplary embodiment, each flake 18 includes a plurality of alternating layers 20, 22, 24, 26, 28 of dielectric materials 30, 32, 34, 36, 38. Adjacent layers 20, 22, 24, 26, 28 are formed of different dielectric materials 30, 32, 34, 36, 38 that have different refractive indexes in the visible spectrum range. In an exemplary embodiment, the alternating layers 20, 22, 24, 26, 28 of dielectric materials 30, 32, 34, 36, 38 with different refractive indexes improves the total reflection of light in the visible spectrum range to provide a highly reflective, mirror-like or metal appearance. In particular, an incoming light ray(s) (indicated by single headed arrow 40) traveling through the paint or resin matrix 16, which has a refractive index of, for example about 1.5, impinges on the flake 18 and portions of the light ray(s) 40 are reflected back (indicated by arrows 42, 44, 46, 48, 50, 52) at each interface where there is a change in refractive index to improve the total reflection of the light ray 40 from the flake 18 and provide an enhanced metal appearance. Multiple reflection, absorption, and transmission events occur at each interface between the alternating layers.
In an exemplary embodiment, the dielectric materials 30, 32, 34, 36, 38 of adjacent layers 20, 22, 24, 26, 28 have one layer with a refractive index of from about 1.25 to about 2.0 and the other layer with a refractive index of from about 2.0 to about 3.0, for example, from about 1.25 to about 1.75 and from about 2.25 to about 2.75, respectively.
In an exemplary embodiment, the dielectric materials 30, 32, 34, 36, 38 are selected from the group of semi-conductors or insulators. In an exemplary embodiment, the dielectric materials 30, 32, 34, 36, 38 are selected from the group of metal oxides. In an exemplary embodiment, the dielectric materials of adjacent layers 20, 22, 24, 26, 28 are SiO2 and TiO2, respectively, for example alternating layers of SiO2 and TiO2 throughout the stack of layers 22, 24, 26, 28.
In an exemplary embodiment, the thickness of each layer 20, 22, 24, 26, 28, the number layers 20, 22, 24, 26, 28, and the concentration of the dielectric pigments 12 in the coating 10 is designed or formulated to further enhance and improve the total reflection of the light ray 40 from the flake 18. In an exemplary embodiment, each of the alternating layers 22, 24, 26, 28 have a corresponding thickness of from about 30 to about 200 nm, for example from about 50 to about 190 nm. In an exemplary embodiment, the plurality of alternating layers 20, 22, 24, 26, 28 is from about 5 to about 15 layers, for example from about 6 to about 12 layers. In an exemplary embodiment, each of the flakes 18 has an overall thickness of from about 500 to about 1200 nm, for example of from about 500 to about 1000 nm. in an exemplary embodiment, each of the flakes has a radius of from about 10 to about 25 μm. In an exemplary embodiment, the dielectric pigments 12 are present in the radar compatible coating 10 in an amount of about 0.5 to 20%, of the radar compatible coating 10.
As discussed above, the dielectric pigments 12 are substantially transparent to radar. In an exemplary embodiment, the dielectric materials that form the alternating layers 20, 22, 24, 26, 28 of the dielectric pigments 12 each have a corresponding dielectric constant of about or less, for example from about 2.5 to about 8 in the radar frequency range of from about 76 to about 81 GHz. In an exemplary embodiment, the dielectric materials that form the alternating layers 20, 22, 24, 26, 28 of the dielectric pigments 12 each have a corresponding permittivity of about 15 or less, for example about 2.5 to about 12 in a radar frequency range of from about 76 to about 81 GHz.
Further,
Referring to
The method 300 further includes forming (STEP 306) a plurality of alternating layers of dielectric materials overlying a substrate. In one example, the plurality of alternating layers of dielectric materials that correspond to the layer structure 202 of the one of the one or more candidate dielectric pigments that is the same or substantially similar in appearance to a target metal-containing coating is deposited overlying a mylar film substrate. This includes depositing (STEP 308) a first layer of a first dielectric material overlying the mylar film substrate, wherein the first dielectric material has a first refractive index in the visible spectrum range; and depositing (STEP 310) a second layer of a second dielectric material overlying the first layer, wherein the second dielectric material has a second refractive index in the visible spectrum range that is different than the first refractive index. In an exemplary embodiment, the layers are deposited using a physical vapor deposition (PVD) process. In an exemplary embodiment, a sol gel dipping process may optionally be used to deposit outer SiO2 layers on the dielectric pigments to improve robustness for mixing the dielectric pigments into the paint or resin matrix.
The method 300 continues by removing (STEP 312) the substrate (e.g., the mylar film substrate, for example by dissolving the mylar or by mechanical means) from the plurality of alternating layers of dielectric materials. Either before, during or after removing (STEP 314), the plurality of alternating layers are broken, crushed, and/or ground into flakes to form the dielectric pigments. The grinding process is intended to create a flake that is of an appropriate diameter to ensure geometric compatibility with various application processes discussed in paragraph [0024]. For instance, an example flake diameter range could be 5 to 25 microns. In certain instances, sieving could be used in order to control the flake diameter and size distribution.
Referring to
A computer readable medium 124 embodies a computer program, where the computer program directs the computer to implement the method and techniques described above. The computer readable medium may be an SD card, a USB storage medium, a floppy disk, a CD-ROM, a DVD, a hard drive, or other devices that are readable by a computer, and that include memory for saving the computer program. In some embodiments, the computer program may be electronically downloaded to the computer, but the downloaded computer program is saved on a tangible device somewhere.
In an exemplary embodiment, the computer program directs the computer to request input from the input device 112, wherein the requested input is directed towards obtaining a reflectance measurement of a target coating to characterize a color of the target coating. The computer program directs the processor 118 to generate one or more candidate formulas to determine color matching to the color of the target coating, where the processor 118 may access one or more mathematical/predictive model(s), an algorithm for example a genetic algorithm, or a software implemented expert system to generate the candidate formulas. The computer program directs the processor 118 to access or otherwise cooperative with one or more predictive models to predict the corresponding color in the corresponding radar property for each of the one or more candidate formulas. Simultaneously or subsequently, the computer program directs the processor 118 to generate a radar compatible coating composition that is the same or substantially similar in appearance to the target coating including color based at least in part on the corresponding color in the corresponding radar property for a selected one of the candidate formulations. The computer program directs the output device 122 to present the radar compatible coating composition including its associated color and radar property, and/or any other information as mentioned above.
While at least one exemplary embodiment has been presented in the foregoing detailed description of the disclosure, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the disclosure. It is understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the disclosure as set forth in the appended claims.
