Backlit Chrome Bodywork Element Without Pinhole Light Leakage
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Solution Overview
Problem
Existing bodywork elements for motor vehicles face challenges such as high manufacturing costs due to precise painting processes, potential chemical damage from solvents, and a 'stardust effect' caused by pinholes in metallized layers, which degrade the logo's appearance under lighting conditions.
Innovation Solution
A two-layer metallized structure is used, with a first layer of aluminium and a second layer of chrome, both etched to form a pattern, eliminating the need for paint and preventing light leakage through pinholes, while ensuring a shiny finish and effective light blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single metallized layer is used, then the manufacturing process is simple, but light leaks through pinholes causing stardust effect
Solution Approach 1:
The patent applies composite materials by using two different metallized layers (first layer and second layer) with distinct optical properties. The first metallized layer provides initial reflectivity, while the second metallized layer with higher opacity blocks light transmission through pinholes, eliminating the stardust effect while maintaining a complete metallized structure.
Solution Approach 2:
The patent implements nesting by placing the second metallized layer over the first metallized layer. This nested structure allows the first layer to provide base reflectivity while the second layer reinforces light blocking, creating a hierarchical arrangement where each layer serves its function within the composite structure.
2Reliability
If opaque paint is applied over metallized coating, then light blocking is improved, but chemical solvents cause cracks in the bodywork
Solution Approach 1:
The patent replaces the chemical painting process with a physical metallized layer deposition process. Instead of applying opaque paint containing chemical solvents that can crack the bodywork, the invention uses physical vapor deposition to create a second metallized layer that provides equivalent or superior light blocking without chemical harm.
Solution Approach 2:
The patent changes the material parameter from organic opaque paint to inorganic metallized material. This parameter change eliminates the chemical solvent issue while maintaining the light blocking function, as the second metallized layer provides opacity through its metallic structure rather than chemical pigments.
3Manufacturing precision
If precise painting masking is performed, then pattern quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces the mechanical masking and painting process with direct physical deposition of metallized layers. The pattern is created through controlled deposition and selective removal of the metallized layers, eliminating the need for time-consuming masking operations while maintaining precise pattern definition through the etching process.
Solution Approach 2:
The patent applies preliminary action by depositing both metallized layers before any pattern definition steps. This allows the complete metallized structure to be formed first, ensuring full coverage and light blocking, and then the pattern is created through selective etching, which is more efficient than attempting to mask and paint complex patterns.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces manufacturing costs, minimizes chemical damage, and eliminates the 'stardust effect' by using sequential metallized layers for enhanced logo visibility and aesthetic appeal in varying lighting conditions.
Implementation Method 1
The first layer of metal deposit contributes to a shiny or glossy reflection of the bodywork, in particular in daylight conditions when light is reflected on the external face
Implementation Method 2
The second layer of an opaque material is configured to block passage of light rays through the covered zones when the light source is activated
Implementation Method 3
a light source placed behind the internal face of the body... when the lighting conditions decrease, the optical device is turned on and the appearance of the body work is defined by the light going through the zones of the body that are not covered by the opaque paint
Data Source
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AI summary
A motor vehicle bodywork element comprising a body made of a transparent material comprising an internal face (12) and an external face (14) and a light source (4) placed behind the internal face of the body (12), wherein the internal face (12) is covered by a layer of metal deposit (13), said layer of metal deposit (13) being covered by a layer of an opaque material (15), both layers being etched so as to form a pattern visible from the external face (14) of the body (11), wherein the layer of opaque material (15) is a second layer of metal deposit darker than the metal of the first layer (13).