Multi-Layer Dry Plating Coatings for Chipping Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming coatings on vehicle components, such as radiator grilles, fail to provide adequate chipping resistance, scratch resistance, durability, appearance, chemical resistance, and weather resistance while being lightweight and maintaining excellent adhesion between coating layers.
Innovation Solution
A method involving a multi-coating process on a dry plating member, where a color coating agent with modified acrylic resin and pigment is applied and dried, followed by a clear coating agent with polyester-modified acrylic resin and photoinitiator, applied and cured, to form a substrate with undercoat, plating, color, and clear layers, using specific solvent ratios and additives for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single coating layer is applied on the plating member, then the manufacturing process is simple, but the chipping resistance and scratch resistance are insufficient
Solution Approach 1:
The coating system is segmented into multiple functional layers: a color coating layer containing modified acrylic resin for base color and adhesion, and a clear coating layer containing polyester-modified acrylic resin for protection. This segmentation allows each layer to perform its specific function, with the clear layer providing superior chipping and scratch resistance while the color layer provides adhesion and base color.
Solution Approach 2:
The patent uses composite coating materials combining modified acrylic resin with polyester-modified acrylic resin in specific ratios. The color coating agent contains 10-35% modified acrylic resin, while the clear coating agent contains 10-30% polyester-modified acrylic resin. This composite approach leverages the adhesion properties of acrylic resin and the protective properties of polyester-modified resin to achieve both simplicity and durability.
2Quantity of substance
If conventional coating materials are used, then the initial cost is low, but the durability and weather resistance are insufficient
Solution Approach 1:
The patent modifies the chemical parameters of the coating materials by using modified acrylic resin with specific molecular weights (5,000-50,000 g/mol) and polyester-modified acrylic resin with controlled hydroxyl values (30-250 mg KOH/g) and glass transition temperatures (40-90°C). These parameter changes enhance durability and weather resistance while maintaining cost-effectiveness through optimized material composition.
Solution Approach 2:
The clear coating agent uses a composite formulation with polyester-modified acrylic resin (10-30%), acrylic oligomer (5-25%), and acrylic monomer (5-45%), creating a material that provides superior durability and weather resistance compared to conventional single-component coatings, while remaining economically viable.
3Reliability
If thick coating layers are applied to improve protection, then the chipping and scratch resistance improve, but the adhesion between coating layers deteriorates
Solution Approach 1:
The patent optimizes the thickness parameters of each coating layer while maintaining proper adhesion. The color coating layer thickness is controlled to provide sufficient adhesion (10-35% modified acrylic resin), and the clear coating layer thickness is optimized for protection (10-30% polyester-modified acrylic resin). This parameter optimization ensures both strong adhesion and adequate protection without compromising either property.
Solution Approach 2:
The use of composite materials with specific resin compositions ensures proper adhesion even at optimized thicknesses. The modified acrylic resin in the color layer and polyester-modified acrylic resin in the clear layer create chemically bonded layers that maintain strong adhesion while providing the necessary protection against chipping and scratching.
4Reliability
If metal plating is used to provide corrosion resistance, then the durability improves, but the weight increases
Solution Approach 1:
The patent applies thin film coating layers (color coating and clear coating) over the metal plating substrate. These thin films provide additional protection against corrosion and wear while adding minimal weight. The color coating layer with modified acrylic resin and the clear coating layer with polyester-modified acrylic resin create a protective film structure that enhances durability without significantly increasing the overall component weight.
Solution Approach 2:
The composite coating system combines metal plating with organic resin coatings to create a multi-material composite structure. The metal provides base corrosion resistance, while the modified acrylic and polyester-modified acrylic resins provide additional protective layers that enhance durability and appearance while maintaining lightweight characteristics compared to conventional metal-only or thick-coating solutions.
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 method achieves a lightweight, high-adhesion, multi-coated article with excellent chipping resistance, scratch resistance, durability, chemical resistance, and weather resistance, suitable for replacing conventional metal parts with improved appearance and mechanical properties.
Implementation Method 1
drying the applied color coating agent to form a color coating layer
Implementation Method 2
curing the applied clear coating agent to form a clear layer
Data Source
AI summary
Disclosed are methods of forming a multiple coating on a dry plating member and a molded article manufactured using the same. The method may include applying a color coating agent onto a surface of a plating layer of a plating member and then drying the applied color coating agent to form a color coating layer, and applying a clear coating agent onto a surface of the color coating layer and curing the applied clear coating agent to form a clear layer, wherein the plating member includes a substrate, an undercoat layer formed on a surface of at least a part of the substrate, and a plating layer formed on a surface of the undercoat layer.