Patent Application
20230129032
The present invention relates to a resin sheet and a radar system.
Radars have been used to detect objects. Adjusting members allowing transmission of radio waves from radars therethrough have been known.
For example, a system including a radar sensor and an adjusting member is described in Patent Literature 1. This system is to be mounted on a motor vehicle so that the adjusting member will allow transmission of a radio wave from the radar sensor therethrough. The adjusting member includes at least one layer that reflects a portion of the radio wave. The adjusting member includes an additional layer configured based on a thickness and a permittivity suitable for reducing reflection of the radio wave. The adjusting member is a bumper. The radar sensor is, for example, a 77-GHz radar.
Patent Literature 1: US 2015/0109162 A1
In the technique described in Patent Literature 1, the adjusting member includes the additional layer configured to reduce reflection of the radio wave. However, in Patent Literature 1, adjustment of transmission of a millimeter wave from a millimeter-wave radar using a frequency-modulated continuous wave (FMCW) is not taken into consideration.
Therefore, the present invention provides a resin sheet that is advantageous in view of adjusting transmission of a millimeter wave from a millimeter-wave radar using an FMCW.
The present invention provides a resin sheet including:
a porous structure configured to adjust transmission of a millimeter wave, wherein
the porous structure has a relative permittivity varying in a thickness direction of the resin sheet such that a difference between average relative permittivities in two adjacent layer portions is a predetermined value or less, the layer portions each having a particular thickness smaller than a wavelength of the millimeter wave,
the porous structure includes a boundary portion being one of the layer portions, the boundary portion having a maximum or minimum average relative permittivity, and
the relative permittivity increases or decreases in stages from end portions of the porous structure toward the boundary portion, the end portions being defined in the thickness direction of the resin sheet.
The present invention also provides a radar system including:
a millimeter-wave radar using a frequency-modulated continuous wave; and
the above resin sheet allowing transmission of a millimeter wave emitted from the millimeter-wave radar through the resin sheet.
The above resin sheet is advantageous in view of adjusting transmission of a millimeter wave from a millimeter-wave radar using an FMCW. With the use of the above radar system, transmission of a millimeter wave from a millimeter-wave radar using an FMCW can be adjusted to a desired state.
It is conceivable to use, for sensing a given object, a millimeter-wave radar using an FMCW. In this case, a given structure such as a housing may be needed to be disposed in a transmission-reception path of a millimeter wave to protect the millimeter-wave radar. It is thought that widening a frequency range of a millimeter wave used for sensing an object using the above millimeter-wave radar is advantageous in improving the accuracy of object sensing. Therefore, the present inventors conducted intensive studies to invent a sheet capable of being included in a structure disposed in a transmission-reception path to protect a millimeter-wave radar, the sheet being capable of improving transmission of a millimeter wave in a wide frequency range. Through much trial and error, the present inventors have newly found that a resin sheet having a given porous structure is advantageous in enhancing transmission of a millimeter wave in a wide frequency range and have completed the present invention.
Hereinafter, embodiments of the present invention will be described with reference to the drawings. The following description describes examples of the present invention, and the present invention is not limited to the following embodiments.
As shown in
The boundary portion 11b may be one of the layer portions 11 and has a minimum average relative permittivity εA. In this case, in the porous structure 10, the relative permittivity decreases in stages from the end portions 12 of the porous structure 10 toward the boundary portion 11b, the end portions 12 being defined in the thickness direction of the resin sheet 1a. With such structural features, a relative permittivity variation rapid enough to affect millimeter-wave propagation can be prevented even when the end portions 12 of the resin sheet 1a are in contact with a substance having a relatively high relative permittivity. Consequently, the resin sheet 1a can reduce reflection of a millimeter wave and can have an increased millimeter-wave transmittance.
Typically, the entire porous structure 10 satisfies the requirement that the difference Δε between average relative permittivities in each two adjacent layer portions 11 is the predetermined value Ve or less.
As shown in
For example, the relative permittivity of the porous structure 10 can be adjusted as described above by varying the porosity in stages in the thickness direction of the porous structure 10.
An average relative permittivity εL in each layer portion 11 of the porous structure 10 can be determined, for example, by the following equation (1). In the equation (1), εK is a relative permittivity of the material of a skeleton of the porous structure 10, εair is the relative permittivity of air, and p is a porosity (0<p<1) in the layer portion 11. The porosity p in each layer portion 11 can be determined, for example, based on the X-ray CT measurement result for the porous structure 10. The relative permittivity of the material of the skeleton of the porous structure 10 is, for example, a relative permittivity measured at 10 GHz by a cavity resonance method.
εL=pεair+(1−p)εK Equation (1)
The particular thickness tL is not limited to a particular value as long as the particular thickness tL is smaller than the wavelength of a millimeter wave. The particular thickness tL is, for example, 100 μm. The predetermined value Ve is not limited to a particular value as long as the resin sheet 1a can have an increased transmittance of a millimeter wave. The predetermined value Ve is, for example, 0.3. The predetermined value Ve is desirably 0.25.
The largest value of Δε in the porous structure 10 is not limited to a particular value. The largest value of Δε is, for example, 0.1 or more and 0.3 or less. This prevents an increase of the thickness of the porous structure 10 when the porous structure 10 is formed such that the relative permittivity increases or decreases in stages in the thickness direction of the resin sheet 1a from the end portions 12 of the porous structure 10 toward the boundary portion 11b.
The thickness of the porous structure 10 is not limited to a particular value as long as the resin sheet 1a can have an increased transmittance of a millimeter wave. The porous structure 10 has a thickness of, for example, 1 mm or more. In this case, the resin sheet 1a can have an increased transmittance of a millimeter wave and can protect a millimeter-wave radar as appropriate.
The thickness of the porous structure 10 is desirably 2 mm or more, and more desirably 3 mm or more. The thickness of the porous structure 10 is, for example, 10 mm or less. This makes it easy to reduce the weight of the resin sheet 1a.
The relative permittivity of the porous structure 10 is not limited to a particular value as long as Δε is 0.3 or less and the relative permittivity increases or decreases in stages from the end portions 12 of the porous structure 10 toward the boundary portion 11b. The porous structure 10 has a relative permittivity of, for example, 1.01 or more and 4.99 or less. In this case, the resin sheet 1a can have an increased transmittance of a millimeter wave more reliably.
The relative permittivity εK of the material of the skeleton of the porous structure 10 is not limited to a particular value as long as the resin sheet 1a can have an increased transmittance of a millimeter wave. The relative permittivity εK is, for example, 2.2 to 5.0.
The material of the skeleton of the porous structure 10 is not limited to a particular material as long as the resin sheet 1a can have an increased transmittance of a millimeter wave. Examples of the material include polyethylene, polypropylene, polystyrene, polyester, polyamide, polyvinyl chloride, polyvinylidene chloride, polybutene, polyacetal, polyphenylene oxide, polymethylmethacrylate, polysulfone, polyethersulfone, polyetherketone, polyetheretherketone, polyamide-imide, polycarbonate, polyarylate, polyimide, fluorine resin, ethylene-propylene resin, ethylene-ethylacrylate, epoxy resin, urethane resin, imide resin, acrylic resin, and norbornene resin. The skeleton of the porous structure 10 may include only one resin material or may include a plurality of resin materials. The skeleton of the porous structure 10 may be formed of a polymer alloy or may be formed of a composite material of a resin matrix and a filler.
The relative permittivity in each of the end portions 12 of the porous structure 10 is not limited to a particular value as long as Δε is 0.3 or less and the relative permittivity increases or decreases in stages from the end portions 12 of the porous structure 10 toward the boundary portion 11b. When the relative permittivity increases in stages from the end portions 12 of the porous structure 10 toward the boundary portion 11b, the relative permittivity in each of the end portions 12 of the porous structure 10 is, for example, 1.8 or less. In this case, the resin sheet 1a can reduce reflection of a millimeter wave and can have an increased millimeter-wave transmittance, for example, when the resin sheet 1a is used such that the end portions 12 of the porous structure 10 is in contact a substance, such as air, having a relatively low relative permittivity. The relative permittivity in each of the end portions 12 of the porous structure 10 may be 1.75 or less, 1.7 or less, or 1.65 or less.
As shown in
The pore diameter of each pore 13 is desirably equal to or less than 7% of the wavelength of a millimeter wave.
A ratio of the number of pores 13 having a pore diameter equal to or less than 10% of the wavelength of a millimeter wave to the number of pores 13 included in the porous structure 10 is, for example, 80% or more, desirably 85% or more, more desirably 90% or more, even more desirably 95% or more, and particularly desirably 98% or more.
The porous structure 10 may have, as pores, only the pores 13 each having a pore diameter equal to or less than 10% of the wavelength of a millimeter wave.
The porous structure 10 has, for example, the pores 13 each having a pore diameter of 20 to 500 μm. In this case, the resin sheet 1a can more reliably reduce reflection of a millimeter wave and can have an increased millimeter-wave transmittance. The pore diameter of each pore 13 may be 450 μm or less, 400 μm or less, or 350 μm or less. The porous structure 10 may have, for example, the pores 13 each having a pore diameter of 20 to 550 μm.
A ratio of the number of pores 13 having a pore diameter of 20 to 500 μm to the number of pores 13 included in the porous structure 10 is, for example, 80% or more, desirably 85% or more, more desirably 90% or more, even more desirably 95% or more, and particularly desirably 98% or more. The porous structure 10 may have, as pores, only the pores 13 each having a pore diameter of 20 to 500 μm. The porous structure 10 may have, as pores, only the pores 13 each having a pore diameter of 20 to 550 μm.
As shown in
The resin sheet 1a may include, for example, a skin layer (not illustrated), and the resin sheet 1a may have one surface formed by the skin layer or may have two surfaces each formed by the skin layer. The skin layer has a thickness, for example, equal to or less than 10% of the wavelength of a millimeter wave. The skin layer having a thickness equal to or less than 10% of the wavelength of a millimeter wave is likely to have a reduced effect on transmission of a millimeter wave even when the skin layer has a relatively high relative permittivity.
The skin layer 20 is typically a solid layer. The thickness of the skin layer 20 is, for example, 550 μm or less, desirably 500 μm or less, more desirably 450 μm or less, even more desirably 400 μm or less.
A resin sheet 1b shown in
For example, a radar system 100 can be provided using the resin sheets 1a and 1b. As shown in
As shown in
As shown in
The radar system 100 may include the resin sheet 1b instead of the resin sheet 1a.
The present invention will be described in more detail by examples. The present invention is not limited to the examples given below. First, methods for evaluation of examples will be described.
<Transmission Loss Improvement Rate>
A transmission coefficient S21 obtained by allowing a millimeter wave with a frequency of 60 to 80 GHz to be perpendicularly incident on each of resin sheets according to Examples and Comparative Examples was measured according to a horn antenna method defined in Japanese Industrial Standards (JIS) R 1679: 2007, and an average transmission loss TAs [dB] in the frequency range of 60 to 80 GHz was determined. Moreover, a transmission coefficient S21 obtained by allowing a millimeter wave with a frequency of 60 to 80 GHz to be perpendicularly incident on another resin substrate A to which no resin sheet was adhered was measured, and an average transmission loss TAR [dB] in the frequency range of 60 to 80 GHz was determined. A transmission loss improvement rate R of each resin sheet was determined by the following equation (2). Table 1 shows the results. It should be noted that the wavelength of a millimeter wave with a frequency of 60 Hz is 5 mm, and the wavelength of a millimeter wave with a frequency of 80 GHz is 3.75 mm. As a measurement apparatus was used a millimeterwave-microwave transmission loss measurement system, Model No. RTS01, manufactured by KEYCOM Corporation or a 30 mmφ transmission loss-return loss measurement system for millimeter waves, Model No. RTS06, manufactured by KEYCOM Corporation.
Improvement rate R=|TAs−TAR|/|TAR| Equation (2)
<Pore Diameters of Pores>
Cross-sections of each of the resin sheets according to Examples and Comparative Examples were measured by X-ray CT scanning using an X-ray CT scanner SKYSCAN 1272 manufactured by Bruker Corporation. The image analysis software Image J provided by the National Institutes of Health, USA, was used for reconstruction from cross-sectional images of the porous structure of each resin sheet, and a smallest pore diameter and a largest pore diameter were calculated. The average of the diameters of inscribed circles of pores in cross-sectional images taken between an interface and a position was determined as the smallest pore diameter, the interface being between one skin layer of the resin sheet and the porous structure, the position being 200 μm away from the interface in the thickness direction of the resin sheet toward the other skin layer of the resin sheet. On the other hand, the average of the diameters of inscribed circles of pores in cross-sectional images was determined as the largest pore diameter, the cross-sectional images being taken between a position being 250 μm away in the thickness direction of the resin sheet from a center defined in the thickness direction of the resin sheet toward one principal surface of the resin sheet and a position being 250 μm away in the thickness direction of the resin sheet from the center toward the other principal surface of the resin sheet. Table 1 shows the results.
<Relative Permittivity>
A relative permittivity of a resin forming the skeleton of the porous structure of each of the resin sheets according to Examples and Comparative Examples was measured at 10 GHz by a cavity resonance method. Table 1 shows the results. Each of the resin sheets according to Examples and Comparative Examples was measured by X-ray CT scanning using an X-ray CT scanner SKYSCAN 1272 manufactured by Bruker Corporation. On the basis of this measurement result, the porosity p in each of a plurality of 100-μm-thick layer portions forming the porous structure and arranged in the thickness direction of the resin sheet was determined. The average relative permittivity εL of each of the layer portions was calculated by the above equation (1) from the thus-determined porosity p, the relative permittivity εK of the resin measured as described above, and the relative permittivity εair (=1.0) of air. The difference Δε between average relative permittivities εL in each two adjacent layer portions of the plurality of layer portions was calculated. Table 1 shows the results. Table 1 also shows an average relative permittivity in two of the plurality of layer portions, the two layer portions forming the end portions of the porous structure.
<Thickness>
Thicknesses of the resin sheets according to Examples and Comparative Examples were measured using a micrometer. Table 1 shows the results.
A mixture of supercritical nitrogen and polypropylene was molded by foaming and injection using a MuCell foaming injection molding apparatus to obtain a resin sheet according to Example 1. The resin sheet according to Example 1 had two principal surfaces each formed by a 350-μm-thick solid skin layer. A portion of the resin sheet according to Example 1 excluding the skin layers had a porous structure. The porous structure had a relative permittivity increasing in stages from the end portions toward a middle portion defined in the thickness direction of the resin sheet. The porous structure had a relative permittivity increasing in stages from one principal surface toward the other principal surface.
A mixture of supercritical nitrogen and polypropylene was molded by foaming and injection using a MuCell foaming injection molding apparatus to obtain a resin sheet according to Example 2. The polypropylene had a relative permittivity of 2.2. The resin sheet according to Example 2 had two principal surfaces each formed by a 300-μm-thick solid skin layer. A portion of the resin sheet according to Example 2 excluding the skin layers had a porous structure. The porous structure had a relative permittivity increasing in stages from the end portions toward the middle portion defined in the thickness direction of the resin sheet.
A mixture of supercritical nitrogen and polypropylene was molded by foaming and injection using a MuCell foaming injection molding apparatus to obtain a resin sheet according to Example 3. The resin sheet according to Example 3 had two principal surfaces each formed by a 150-μm-thick solid skin layer. A portion of the resin sheet according to Example 3 excluding the skin layers had a porous structure. The porous structure had a relative permittivity increasing in stages from the end portions toward the middle portion defined in the thickness direction of the resin sheet.
A mixture of supercritical nitrogen and polyamide 6 was molded by foaming and injection using a MuCell foaming injection molding apparatus to obtain a resin sheet according to Example 4. The polyamide 6 had a relative permittivity of 4.9. The resin sheet according to Example 4 had two principal surfaces each formed by a 400-μm-thick solid skin layer. A portion of the resin sheet according to Example 4 excluding the skin layers had a porous structure. The porous structure had a relative permittivity increasing in stages from the end portions toward the middle portion defined in the thickness direction of the resin sheet.
A mixture of supercritical carbon dioxide and polypropylene was molded by foaming and injection using a MuCell foaming injection molding apparatus to obtain a resin sheet according to Example 5. The resin sheet according to Example 5 had two principal surfaces each formed by a 510-μm-thick solid skin layer. A portion of the resin sheet according to Example 5 excluding the skin layers had a porous structure. The porous structure had a relative permittivity increasing in stages from the end portions toward the middle portion defined in the thickness direction of the resin sheet.
A polypropylene resin ABSORTOMER EP1001 manufactured by Mitsui Chemicals, Inc. and a thermo-expandable microcapsule Matsumoto Microsphere FN-180S manufactured by Matsumoto Yushi-Seiyaku Co., Ltd. were mixed using Labo Plastomill at 100° C. for 15 minutes to obtain a mixture, which was heat-pressed using a hot plate adjusted at 100° C. to produce a 1000-μm-thick sheet having 50-square-millimeter principal surfaces. Labo Plastomill is a registered trademark of Toyo Seiki Seisaku-sho, Ltd. Then, the sheet was expanded at 150° C. for 10 minutes to a thickness of 2000 μm to obtain a resin sheet according to Example 6. The thickness of the resin sheet was adjusted using a brass spacer having a dimension of 2000 μm. A portion of the resin sheet according to Example 6 excluding skin layers had a porous structure. The porous structure had a relative permittivity increasing in stages from the end portions toward the middle portion defined in the thickness direction of the resin sheet.
A mixture of supercritical carbon dioxide and polypropylene was molded by foaming and injection using a MuCell foaming injection molding apparatus to obtain a resin sheet according to Example 7. The resin sheet according to Example 7 had two principal surfaces each formed by a 320-μm-thick solid skin layer. A portion of the resin sheet according to Example 7 excluding the skin layers had a porous structure. The porous structure had a relative permittivity increasing in stages from the end portions toward the middle portion defined in the thickness direction of the resin sheet.
A homogeneous polyethylene foam was cut to a given size to obtain a resin sheet according to Comparative Example 1. The resin sheet according to Comparative Example 1 had a relative permittivity being constant from one principal surface to the other principal surface.
As shown in Table 1, the resin sheets according to Examples had an improvement rate R of 35% or more. On the other hand, the resin sheet according to Comparative Example 1 had an improvement rate R of less than 35%. These indicate that it is advantageous for the porous structure of the resin sheet to have a relative permittivity increasing in stages from the end portions toward the middle portion defined in the thickness direction of the resin sheet, the relative permittivity increasing such that Δε is 0.3 or less.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-064891 | Mar 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/008001 | 3/2/2021 | WO |
