Coat Layer Laser Design Printing Resists Chemical Degradation

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Solution Overview

Problem

Existing decorative methods for vehicle parts, such as laser processing, expose aluminum metallic powder on the surface, leading to deterioration of chemical and oil resistance, compromising the performance and liability of the coated layer.

Innovation Solution

A decorative method involving a coat layer formed with scale-shaped micronized-metallic powder, where a laser is irradiated to thermally deform the powder, reducing its aspect ratio and maintaining the surface state, preventing exposure and ensuring chemical resistance and optical differentiation for clear design printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If laser is irradiated onto the surface of a coat layer to provide laser processing and curve the surface, then designs can be printed on the surface, but the aluminum metallic powder is exposed on the processing section, causing deterioration of chemical resistance and oil-staining resistance

Engineering Contradiction:

Improvedesign printing capabilityVSAvoidchemical resistance and oil-staining resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the physical state of the aluminum metallic powder from scale-shaped to spherical through thermal deformation by laser irradiation. This parameter change in shape (from high aspect ratio to low aspect ratio) allows the powder to remain embedded in the coat layer while still enabling design printing through optical property changes, thus maintaining chemical and oil resistance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical surface curving method with a thermal field method. Instead of mechanically deforming the coat layer surface to create design patterns, laser thermal energy is used to deform the aluminum powder particles internally, changing their optical properties to create visible design patterns without altering the external surface topology.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If the surface of the coat layer is curved into a hollow shape by laser irradiation, then designs are printed on the surface, but the performance of the coat layer deteriorates, thus not securing sufficient product liability

Engineering Contradiction:

Improvedesign printing qualityVSAvoidproduct liability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent changes the aspect ratio parameter of the aluminum metallic powder from high (scale-shaped) to low (spherical) through thermal deformation. This internal parameter change enables design printing through optical property modification while keeping the external surface intact, thereby maintaining product liability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent shifts the design printing mechanism from external surface topology (3D hollow shapes) to internal particle morphology (2D optical property changes). By changing the shape of aluminum powder particles within the coat layer, designs are created through optical reflection differences rather than surface curvature, maintaining surface integrity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This method maintains the performance of the coat layer, preventing surface curvature and exposure of metallic powder, thus ensuring excellent product liability and improved design quality by accentuating hidden pigments and maintaining chemical resistance.

Implementation Method 1

a laser is irradiated on the condition of being able to maintain the same state of the surface of the coat layer before and after irradiating the laser, so as to reduce the aspect ratio of the micronized-metallic powder... which laser irradiation eventually thermally deforms the first micronized-metallic powder

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

laser irradiation eventually thermally deforms the first micronized-metallic powder in the coat layer to print the designs on the film

Methodology Applied

Scientific EffectThermal deformation: Deformation

Data Source

PatentUS9545814B2Decorated parts with design containing coat layer

Publication Date: 2017.01.17 TRINITY IND CORP

AI summary

A method for decorating a given part is designed to print designs onto a coat layer deteriorating the coat layer on the surface of the given part. In the coat layer-forming process, in spreading the metallic-coating material containing aluminum flake onto the surface of the resin compact, the coat layer is formed on the surface of it. In a laser-printing process, a laser is irradiated on the condition of being able to maintain the same state of the coat layer before and after irradiating the laser, so as to reduce the aspect ratio of the micronized-metallic powder, which is the average value of the ratio of the maximum dimension of the micronized-metallic powder to the average value of the minimum dimension of the micronized-metallic powder, which laser irradiation eventually thermally deforms the first scale-shaped micronized-metallic powder into a spherical shape in the coat layer to print designs on the film.