Decorative Laminate Gloss Layer for Paint-Like Vehicle Finishes
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Solution Overview
Problem
The use of paint in coating exterior members of mobile bodies, such as automobiles, leads to the emission of volatile organic compounds and carbon dioxide, posing environmental concerns.
Innovation Solution
A decorative laminate with a design layer including a glossy layer and optional additional layers, such as a coloring layer and reflective layer, is used to create a design similar to paint without the need for traditional paint application, reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If paint is used to coat exterior members, then a good appearance is achieved, but volatile organic compounds and carbon dioxide are emitted causing environmental harm
Solution Approach 1:
The patent uses a decorative film with a decorative layer that copies the appearance of painted surfaces. The decorative layer contains colorants and glossy materials that replicate the visual characteristics of paint, allowing the exterior member to achieve a similar aesthetic without using actual paint coatings that emit volatile organic compounds.
Solution Approach 2:
The patent replaces the chemical coating process (paint application and drying) with a physical lamination process. Instead of applying liquid paint that requires drying and emits volatile organic compounds, the decorative film is applied as a pre-manufactured layer containing all necessary color and gloss properties, eliminating the harmful emission source.
2Ease of manufacture
If paint is used to coat exterior members, then a good appearance is achieved, but energy is consumed in the drying step
Solution Approach 1:
The decorative film is manufactured separately with the desired appearance properties already embedded in the decorative layer. This eliminates the need for energy-intensive drying processes required when applying liquid paint, as the film application is a simple lamination process that does not require thermal drying.
3Object-generated harmful factors
If a decorative film is used instead of paint, then volatile organic compound and carbon dioxide emissions are reduced, but the design displayed must be made closer to that of paint
Solution Approach 1:
The decorative layer is constructed as a composite material system containing colorants, glossy materials, and transparent resins in specific combinations. This composite structure enables the decorative film to achieve paint-like appearance qualities including color accuracy, gloss level, and visual depth, thereby meeting the design quality requirement while maintaining emission reduction benefits.
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 decorative laminate provides a design comparable to paint while minimizing volatile organic compound and carbon dioxide emissions, offering an environmentally friendly alternative.
Implementation Method 1
the design layer includes a glossy layer including a glossy material
Data Source
Figure 1~2
Figure 2A~2B
Figure 3~5
AI summary
A decorative laminate 30 has a first surface 30A and a second surface 30B opposite to the first surface 30A. The decorative laminate 30 includes a base material layer 31, a surface layer 33 disposed nearer to the first surface 30A than the second surface 30B with respect to the base material layer 31, and a design layer 40 supported by the base material layer 31. The design layer 40 includes a glossy layer 41 including a glossy material 41b.