Coated Object with Adjustable Coating Layers for Automotive Panels
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Solution Overview
Problem
Existing coating technologies for automotive body panels face challenges in achieving a balance between mechanical and chemical properties, such as stone chipping resistance and chemical resistance, without increasing overall costs. Current methods produce clearcoat layers with higher stone chipping resistance at the expense of chemical resistance, and vice versa.
Innovation Solution
A process is developed to apply different coating compositions to various target areas on an object, ensuring that each coating layer has properties matched to the specific requirements of the area it covers. This involves identifying target areas with unique sets of properties, providing specific coating compositions that result in coating layers with adjustable properties, and applying these compositions to the corresponding target areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If clearcoat layers with higher stone chipping resistance are produced, then mechanical properties are improved, but chemical resistance deteriorates
Solution Approach 1:
The patent applies different coating compositions to different target areas based on their specific property requirements. Areas requiring high stone chipping resistance receive formulations optimized for mechanical durability, while other areas receive formulations optimized for chemical resistance, allowing each zone to have locally optimized properties without compromising the other.
Solution Approach 2:
The coating process segments the object into multiple target areas with different property requirements. By dividing the coating application into distinct zones and applying different compositions to each, the system resolves the contradiction between mechanical and chemical resistance properties that would be present in a uniform coating approach.
2Strength
If clearcoat layers with higher scratch resistance and light resistance are produced, then mechanical properties are improved, but production costs increase
Solution Approach 1:
The patent implements local quality by applying high-performance, cost-intensive coating compositions only to specific target areas where scratch resistance and light resistance are critical, rather than uniformly across the entire object. This localized approach reduces overall production costs while maintaining necessary performance levels.
Solution Approach 2:
The system applies partial action by providing enhanced scratch and light resistance properties only to the extent necessary for specific target areas, rather than over-engineering all areas. This avoids excessive material and cost expenditure while achieving sufficient performance where required.
3Ease of manufacture
If uniform coating composition is applied to all areas, then manufacturing simplicity is maintained, but property optimization for specific areas is lost
Solution Approach 1:
The patent introduces dynamics into the coating process by enabling flexible selection and application of different coating compositions based on the specific requirements of each target area. This dynamic approach allows the system to adapt to varying property requirements across different zones while maintaining manufacturing efficiency through automated or semi-automated application processes.
Data Source
AI summary
Described herein is a process for producing a coated object including a plurality of target areas where at least part of the plurality of target areas is coated with coating layers having adjustable properties. Also described herein are a method of using the process for preparing a coated object including target areas requiring coating layers having different properties. and a system for applying—utilizing an application device—at least two coating compositions resulting in coating layers having adjustable properties to an object including a plurality of target areas, where at least part of the plurality of target areas have a different set of properties.