VEHICLE WITH MULTI-COLORED PAINTING

Abstract

A method of providing a vehicle with a multi-color paint finish, the method comprising: applying a first paint finish of a first color to a body of the vehicle, with a panel of the vehicle removed from the body of the vehicle; applying a film to the panel, the film comprising a second paint finish of a second color different from the first color; and attaching the panel to the body of the vehicle.

Description

INTRODUCTION

[0001] The information provided in this section is intended to provide a general context for the disclosure. Work by the inventors identified herein, to the extent described in this section, as well as aspects of the description that may not be prior art at the time of filing, are neither expressly nor impliedly admitted as prior art over the present disclosure.

[0002] The present disclosure relates to a vehicle having a multi-colored paint finish and methods for applying the multi-colored paint finish.

[0003] Vehicle bodies are often painted in a single color, meaning the entire body is painted in a single color. Some vehicle bodies are painted in two colors, meaning different areas of the body are painted in different colors. For example, in a two-tone vehicle, the roof and an area of ​​the body below the roof might be painted in different colors. A two-tone paint job generally requires more time and effort than a single-color job. SUMMARY

[0004] The present disclosure includes, in various features, a method of providing a vehicle with a multi-color paint finish, the method comprising: applying a first paint finish of a first color to a body of the vehicle, wherein a panel of the vehicle is removed from the body of the vehicle; applying a film to the panel, wherein the film comprises a second paint finish of a second color different from the first color; and attaching the panel to the body of the vehicle.

[0005] In other features, the panel is a roof panel.

[0006] In other features, the plate is a door plate.

[0007] In further features, applying the film to the plate comprises applying the film by a thermal vacuum forming process.

[0008] In further features, the present disclosure includes pretreating the plate by anodizing the plate prior to applying the film to the plate.

[0009] In further features, the present disclosure includes pretreating the plate with an electrocoating prior to applying the film to the plate.

[0010] In further features, the present disclosure includes applying the first coating to a first region and a second region of the panel prior to applying the film to the panel, masking the first region to cover the first coating, applying the film to the second region over the first coating by thermal vacuum forming, and unmasking the first region.

[0011] In further features, the present disclosure includes masking a first region of the plate prior to applying the film to the plate and applying the film by thermal vacuum forming to a second region of the plate different from the first region.

[0012] In further features, the film comprises an adhesive; and applying the film to the plate further comprises placing the film on a fixture with the adhesive facing outward, placing the plate on the fixture such that the film adheres to the plate by the adhesive, and wrapping the film around the plate.

[0013] In further features, the film further comprises a third coating of a third color which is different from the second color.

[0014] In further features, the present disclosure includes attaching a cover to the panel in a boundary region between the second coating and the third coating.

[0015] In further features, the present disclosure includes forming the film by applying the second coating and the third coating to the film.

[0016] In further features, the present disclosure includes aligning the plate to the vehicle by moving the plate locating elements of the plate in cooperation with the vehicle locating elements of the vehicle.

[0017] In further features, the present disclosure includes aligning the plate on the vehicle with an image processing camera.

[0018] The present disclosure further includes, in various features, a method of providing a vehicle with a multi-color paint finish, the method comprising: applying a first paint finish of a first color to the vehicle; forming a paint film comprising a second paint finish of a second color and a third paint finish of a third color, the second color being different from the third color; applying the paint film to a panel of the vehicle by thermal vacuum forming; and attaching the panel to the vehicle.

[0019] In further features, forming the color film further comprises: applying the second coating of the second color over an entire width of the paint film; curing the second coating; and applying the third coating of the third color to less than an entirety of the second coating.

[0020] In further features, forming the paint film further comprises simultaneously applying the second paint coating to a first region of the paint film and applying the third paint coating to a second region of the paint film that is different from the first region.

[0021] In further features, the present disclosure includes aligning the plate, the second color, and the third color with the vehicle by moving plate locating elements of the plate in cooperation with vehicle locating elements of the vehicle; and verifying the alignment of the plate, the second color, and the third color with an image processing camera.

[0022] The present disclosure further encompasses, in various features, a vehicle having a multi-color paint finish, the vehicle comprising: a first paint finish of a first color applied to a body of the vehicle; and a panel attached to the body, the panel comprising a film adhered to the panel by thermal vacuum forming, the film comprising a second paint finish of a second color and a third paint finish of a third color, wherein at least one of the second color and the third color is different from the first color.

[0023] In other features, the plate is a roof plate, a door plate or a hood plate.

[0024] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are provided for purposes of illustration only and are not intended to limit the scope of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, in which: Fig. 1 is a plan view of an exemplary vehicle having an exemplary multi-color paint scheme according to the present disclosure, the vehicle including a body painted with a first paint scheme of a first color and a roof panel covered with a film comprising a second paint scheme of a second color different from the first color; Fig. 2A, Fig. 2B and Fig. 2C illustrate an exemplary method for applying the film to the roof panel by thermal vacuum forming; Fig. 3 illustrates a method of providing a vehicle with a multi-color paint finish according to the present disclosure; Fig. 4A and Fig. 4B illustrates the application of the film having the second coating of the second color to a window frame of an exemplary vehicle door according to another method of the present disclosure; Fig. 5A and Fig. 5B illustrates the application of the film having the second coating of the second color to the window frame according to an additional method of the present disclosure, the method comprising using a holding device to hold the film prior to applying the film to the window frame; Fig. 6 illustrates an exemplary vehicle door panel having the film covering the window frame and a body of the door panel, the film comprising the second finish of the second color on the window frame and a third finish of a third color different from the second color on the body; Fig. 7 illustrates an exemplary method according to the present disclosure for producing the film comprising both the second coating of the second color and the third coating of the third color; Fig. 8 illustrates a system for producing a paint film according to the present disclosure for producing a paint film having two or more colors; and Fig. 9 illustrates a system according to the present disclosure for aligning the roof panel on the vehicle.

[0026] Reference symbols may be reused in the drawings to identify similar and / or identical elements. DETAILED DESCRIPTION

[0027] Fig. 1 illustrates an exemplary vehicle 10 with a multi-color paint finish according to the present disclosure. Although the figures illustrate the multi-color paint finish of a vehicle, the present disclosure also applies to non-vehicle applications. The methods and systems set forth herein for providing a multi-color paint finish therefore apply to vehicles and any other suitable structures, surfaces, etc.

[0028] Vehicle 10 of the Fig. 1 comprises a body 12 with various panels, e.g., door panels 14, a roof panel 16 and a hood panel 18. In the example of Fig. 1, the body 12, with the exception of the roof panel 16, is painted with a first paint coating 50 in a first color. The first paint coating 50 is applied in any suitable manner, e.g., by spraying the first paint coating 50 onto the panels of the body 12.

[0029] The roof panel 16 is covered with a film 110. The film 110 may be made of any suitable material, e.g., any suitable polymer material, including, but not limited to, acrylic polyurethane, acrylonitrile butadiene styrene (ABS), high impact polystyrene (HIPS), or polyethylene terephthalate glycol (PETG). The film 110 includes a second coating 52. The second coating 52 has a second color that is different from the first color of the first coating 50. As shown in Fig. As illustrated in Figure 2A, the film 110 includes an outer film surface 112 to which the second coating 52 is applied. An inner film surface 114 of the film 110 faces the outer film surface 112. The inner film surface 114 includes an adhesive.

[0030] The film 110 is applied to the roof panel 16 by thermal vacuum forming, as explained herein. The film 110 may also be applied to the roof panel 16 in any other suitable manner. Fig. 2A, Fig. 2B and Fig. 2C illustrate an exemplary method for applying the film 110 to the roof panel 16 by thermal vacuum forming. The method according to the Fig. 2A, Fig. 2B and Fig. 2C can also be used to attach the film 110 to any other panel of the vehicle 10 as well as to any other suitable surface.

[0031] With initial reference to Fig. 2A, the film 110 and the plate 16 are arranged in a vacuum box 210, and more particularly in an airtight chamber 220 of the vacuum box 210. The plate 16 includes an outer plate surface 30 that faces an inner plate surface 32. To apply the film 110 to the plate 16 by thermal vacuum forming, the film 110 is heated, and then air is sucked out of the airtight chamber 220 through an outlet 222 by applying a vacuum. Referring to Fig. 2B and Fig. 2C, the vacuum pulls the inner film surface 114 onto the outer plate surface 30. The adhesive on the inner film surface 114 fixes the film 110 to the outer plate surface 30. In the example of Fig. 2C, the film 110 covers the entire outer plate surface 30. Excess portions of the film 110 are removed by any suitable means, for example by laser cutting.

[0032] Fig. 3 illustrates an exemplary method 310, according to the present disclosure, for providing the vehicle 10 with a multi-color paint finish. The method 310 is applicable to any suitable vehicle and may be used in any other suitable application to achieve a multi-color paint finish. With initial reference to block 312, one or more panels of the body 12 (e.g., door panels 14, roof panels 16, hood panels 18) are removed from the vehicle 10 to provide the removed panels with a different color than the remainder of the body 12. After removing the panel(s), the body 12 is painted with the first paint coating 50 of the first color using a suitable painting process. In block 314, the first paint coating 50 is cured. Before, after, or during the application of the first paint coating 50, the removed panel is pretreated in block 320.Pretreatment depends on the composition of each individual body panel. For example, a composite body panel does not require pretreatment. A steel, aluminum, or mixed metal body panel is pretreated by applying a thin foil or phosphate and electrocoating to the panel. For all aluminum body panels, the panel can be treated with any suitable anodizing process.

[0033] After the panel has been pretreated in block 320, the process 310 proceeds to block 322. In block 322, the film 110 with the second coating 52 of the second color (which is different from the first color of the first coating 50) is applied to the detached panel. The film 110 can, for example, be applied to the roof panel 16, as shown in Fig. 1, Fig. 2A, Fig. 2B and Fig. 2C. The film 110 may also be applied to any other suitable panel. For example, the film 110 may be applied to one or more door panels 14, the hood panel 18, or any other suitable panel of the body 12, or at other locations on the vehicle 10. From block 322, the method 310 proceeds to block 324. In block 324, the excess film 110 is trimmed from the panel to which the film was applied, e.g., by laser cutting. In block 330, the panel with the film 110 is attached to the body 12 of the vehicle 10, which includes the first paint finish 50 of the first color, to provide the vehicle 10 with a multi-color paint finish. Additional films 110, including the second paint finish 52 or a paint finish of a different color, may also be applied to any other panel of the body 12.

[0034] Fig. 4A and Fig. 4B illustrate the application of the film 110 to a window frame of the door panel 14. The door panel 14 includes a first region 20 comprising a body of the door panel 14 and a second region 22 comprising the window frame of the door panel 14. Prior to application of the film 110, the entire door panel 14 (including the first region 20 and the second region 22) may be painted with the first paint finish 50, painted with a different color paint finish, or the door panel 14 may be in a shell state. The first region 20 is masked in any suitable manner, for example, with a suitable mask 60, as shown in Fig. 4A. The film 110 is then applied to the second surface 22, which in this example is the window frame. The film 110 can be thermally vacuum formed in the manner described above and in Fig. 2A-2C with respect to the roof panel 16 or in any other suitable manner. The mask 60 is removed after the film 110 has been applied. The result is a door panel 14 in which the first area 20 is painted with the first coating 50 of the first color and the second area 22 covered with the film 110 is painted with the second coating 52 of the second color.

[0035] Fig. 5A and Fig. 5B illustrate the use of a retaining device 410 to facilitate the application of the film 110 to a second portion of the door panel 14. With particular reference to Fig. 5A, the retainer 410 is generally sized and shaped to conform to the size and shape of the door panel 14. The retainer 410 is shaped like an outer surface of the door panel 14, but slightly larger to allow excess portions of the film 110 to be wrapped around the door panel 14 as described below. Thus, the retainer 410 includes a body 412 that is generally sized and shaped to conform to the size and shape of the first portion 20 of the door panel 14. The retainer 410 further includes a frame 414 that is generally sized and shaped to approximate the second portion 22 of the door panel 14. To apply the film 110 to the second portion 22 of the door panel 14, the film 110 is first placed onto the frame 414 of the retainer 410 with the inner film surface 114 facing up. The inner film surface 114 comprises an adhesive as described above in the description of the Fig. 2A-2C explained.

[0036] The film 110 can be pre-cut and placed only on the frame 414. Alternatively, the film 110 can be placed over a larger portion of the retaining device 410, for example, over the frame 414 and the body 412. Any portion of the film 110 that is not to be transferred to the door panel 14 is covered by a suitable mask 60. The mask 60 has a non-adhesive surface to prevent the inner film surface 114 of the film 110 from adhering to it.

[0037] The fixture 410 includes a plurality of holes through which a vacuum can be drawn from the back of the fixture 410. The film 110 is heated by the fixture 410, and a vacuum is drawn from the back of the fixture 410 to form the film 110. Pressure can be applied to the film 110 from the front of the fixture 410 to press the film 110 against the fixture 410.

[0038] With reference to Fig. 5B: After the film 110 has been placed on the holding device 410, the door panel 14 is placed on the holding device 410 and pressed against the film 110. As a result, the adhesive on the inner film surface 114 bonds the film 110 to the second region 22 of the door panel 14. Excess material of the film 110 is wrapped around the second region 22 of the door panel 14 using a suitable crimping tool (e.g., a cylindrical rolling tool) and sealed in a suitable manner. Excess portions of the film 110 can also be trimmed off, e.g., using a laser cutter. The first region 20 of the door panel 14 can be painted in any suitable color by any suitable means. For example, the first region 20 can be painted with the first paint 50 before applying the film 110.

[0039] Fig. Figure 6 illustrates the door panel 14 with the film 110 applied thereto by thermal vacuum forming (as described above in the description of Fig. 2A, Fig. 2B, Fig. 2C) or in any other suitable manner. The film 110 is applied to both the first region 20 and the second region 22 of the door panel 14. The portion of the film 110 covering the second region 22 is painted with the second paint 52 in the second color. The portion of the film 110 covering the first region 20 is painted with a third paint 54 in a third color. Any suitable covering 70 (e.g., in the form of a trim strip) is applied to a transition region between the second paint 52 and the third paint 54 on the door panel 14. The covering 70 advantageously conceals the transition region. Thus, in the example of Fig. 6, the film 110 may include both the second coating 52 and the third coating 54 having different colors to provide the door panel 14 with a two-color configuration. The film 110 may further include more than two coating colors to provide the door panel 14 with more than two colors.

[0040] Fig. 7 illustrates an exemplary method 510 for applying multiple finishes to the film 110. In block 512 of the method 510, a suitable primer layer is first applied to the film 110. In block 514, the primer layer is cured in a suitable manner, e.g., by thermal or ultraviolet curing. The second finish 52 and the third finish 54 can be applied individually or simultaneously. If applied individually, the method 510 proceeds to block 516. In block 516, a first base coat of a first color is applied across the entire width of the film 110. The second finish 52 of the second color can, for example, be applied across an entire width of the film 110. In block 518, the first base coat, e.g., the second color 52, is cured by thermal or ultraviolet curing.In block 520, a second base coat of a second color is applied to a portion of the film 110 where the second color is desired. Thus, if the second coating 52 is applied across the entire width of the film 110, the third coating 54 is applied over a portion of the second coating 52 where the third color is desired. In block 522, the second base coat is cured in a suitable manner, e.g., with an ambient or thermal flash. In block 524, a suitable clear coat is applied to the entire film 110, e.g., over the second coating 52 and the third coating 54. In block 526, the clear coat layer is cured by thermal or ultraviolet curing.

[0041] The first base coat and the second base coat may also be applied simultaneously. After the primer coat has cured in block 514, the method 510 may, for example, continue with block 530. In block 530, both the first and second base coats are applied simultaneously. From block 530, the method proceeds to block 522. Fig. 8 illustrates an exemplary system 610 for simultaneously applying the first base coat and the second base coat.

[0042] In the example of Fig. 8, the first base coat may be the second coating 52 of the second color, and the second base coat may be the third coating 54 of the third color. The system 610 includes a first roller 612 and a second roller 614. The film 110 is rolled from the first roller 612 onto the second roller 614. The system 610 includes a first hopper 620 and a second hopper 622. In the example shown, the first hopper 620 includes the second coating 52, and the second hopper 622 includes the third coating 54.

[0043] The first hopper 620 is disposed over a first portion of the film 110, and the second hopper 622 is disposed over a second portion of the film 110. The first and second portions are adjacent to each other, with a separator 640 therebetween to separate the two colors and maintain a solid dividing line between the two colors on the film. A plurality of dryers 630 are disposed between the first roller 612 and the second roller 614. As the film is rolled from the first roller 612 to the second roller 614, the first base layer is applied to the film 110 from the first hopper 620, and the second base layer is applied to the film 110 from the second hopper 622. The first and second base layers are dried by the dryer 630 before reaching the second roller 64.

[0044] In the example of Fig. 8, the first base coat is the second coating 52 and the second base coat is the third coating 54. However, any suitable coating in any color may be applied to the film 110 via the first and second funnels 620, 622. The position of the first and second funnels 620, 622 may be arranged at any suitable location relative to the film 110. In the example shown, the first and second funnels 620, 622 deposit the respective coatings next to each other. However, the funnels 620, 622 may be arranged in any other suitable position relative to the film 110. Although Fig. 8 illustrates two hoppers, however, more than two hoppers can be used to apply additional base coats with additional colors. A coating distributor collects the coating from the hoppers 620, 622 and distributes it evenly on the film 110. The separator 640 separates the coating from the two hoppers 620, 622 and creates a fixed parting line on the film 110. The separator 640 is movable to adjust the parting line on the films 110.

[0045] With reference to Fig. 9, the roof panel 16 includes a plurality of locating elements 80, each of which is configured to cooperate with a corresponding locator of the vehicle 10. In the illustrated example, the locating elements 80 are formed as tabs extending from an underside of the roof panel 16. The locating elements 80 are configured to be received by suitable receptacles of the vehicle 10, which are arranged to ensure proper alignment of the roof panel 16 and the paint film 110 applied thereto. Any other painted panels of the vehicle 10 may also include the locating elements 80, e.g., the door panels 14, the hood panel 18, etc.

[0046] Once the painted panel is mounted on the vehicle 10, its alignment can be checked by any suitable means, for example, using a suitable image processing inspection system. In the example of Fig. 9, the robot arms 710 include image processing cameras 720. The robot arms 710 are configured to move the cameras 720 to check the alignment of the painted features of the roof 16 or another panel of the vehicle 10. In the example of Fig. 9, the roof panel 16 includes the film 110 painted with the second paint 52, which is arranged as a stripe along the center of the roof panel 16. The locating elements 80 are configured to interact with images of the vehicle 10 to properly position the stripe. The robotic arms 710 move the cameras 720 to scan the stripe and surrounding areas of the vehicle 10 and verify the proper placement of the stripe. The cameras 720 can be configured to verify the alignment of other painted features of the roof panel 16 or another panel of the vehicle 10.

[0047] The foregoing description is merely illustrative and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure may be embodied in a variety of forms. Although this disclosure contains particular examples, the true scope of the disclosure should not be so limited because other modifications will become apparent upon a study of the drawings, the specification, and the following claims. It is to be understood that one or more steps within a method may be performed in a different order (or simultaneously) without changing the principles of the present disclosure.Although each of the embodiments described above includes certain features, one or more of those features described with respect to any embodiment of the disclosure may be implemented in any other embodiment and / or combined with features of any other embodiment, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and combinations of one or more embodiments with each other remain within the scope of this disclosure.

[0048] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "adjacent," "over," "above," "below," and "disposed." When a relationship between a first and a second element is not explicitly described as "direct" in the above disclosure, that relationship may be a direct relationship, with no other intervening elements present between the first and second elements, or it may be an indirect relationship, with one or more intervening elements (either spatial or functional) present between the first and second elements.As used herein, the phrase "A, B and / or C" should be construed as logical (A ORed with B ORed with C) using a non-exclusive logical OR, rather than as "at least one of A, at least one of B and at least one of C".

[0049] In the figures, the direction of an arrow, as indicated by the arrowhead, generally indicates the flow of information (e.g., data or instructions) of interest for the representation. For example, if element A and element B exchange a lot of information, but the information passed from element A to element B is relevant for the representation, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is passed from element B to element A. For information sent from element A to element B, element B may further send requests for the information to element A or acknowledge receipt of it.

Claims

[1] A method of providing a vehicle with a multi-colored paint finish, the method comprising: Applying a first coat of paint of a first color to a body of the vehicle, wherein a panel of the vehicle is removed from the body of the vehicle; Applying a film to the plate, the film comprising a second coating of a second color different from the first color; and Attaching the plate to the vehicle body. [2] The method of claim 1, wherein the panel is a roof panel. [3] The method of claim 1, wherein the panel is a door panel. [4] The method of claim 1, wherein applying the film to the plate comprises applying the film by a thermal vacuum forming process. [5] The method of claim 1, further comprising pretreating the plate by anodizing the plate prior to applying the film to the plate. [6] The method of claim 1, further comprising pretreating the plate with an electrocoating prior to applying the film to the plate. [7] The method of claim 1, further comprising applying the first coating to a first region and a second region of the panel prior to applying the film to the panel, masking the first region to cover the first coating, applying the film to the second region over the first coating by thermal vacuum forming, and unmasking the first region. [8] The method of claim 1, further comprising masking a first region of the plate prior to applying the film to the plate, applying the film by thermal vacuum forming to a second region of the plate different from the first region. [9] The method of claim 1, wherein: the film comprises an adhesive; and applying the film to the plate further comprises placing the film on a holding device with the adhesive facing outwards, placing the plate on the holding device such that the film adheres to the plate by the adhesive, and wrapping the film around the plate. [10] The method of claim 1, wherein the film further comprises a third coating of a third color different from the second color.

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