Vehicle Emblem Coating Edge Protection via Masking and Back-Coating Wrap
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Solution Overview
Problem
Vehicle emblems are prone to defects and degradation, which can diminish the perceived quality and reputation of the vehicle manufacturer, as existing attachment methods do not effectively protect the emblem coatings from environmental factors and contact with chrome plating.
Innovation Solution
A method involving vacuum metalizing a first coating of aluminum onto a selected portion of the emblem, with a back coating wrapping around the distal edge surface to prevent contact with chrome plating, and a mask positioning technique to ensure the coating does not cover the edge, combined with a fixture for precise application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the emblem coating is applied to cover the entire surface including edges, then the aesthetic appearance is improved, but the coating becomes susceptible to bimetallic corrosion and delamination
Solution Approach 1:
The patent applies different coating properties to different regions of the emblem. The first coating (aluminum) is applied only to visible surfaces while deliberately excluding the distal edge surface, which then receives a second coating. This local differentiation prevents bimetallic corrosion at edges while maintaining aesthetic appearance on visible surfaces.
Solution Approach 2:
The mask serves as an intermediary tool during the coating process to precisely control where the first coating is applied. By positioning the mask adjacent to the emblem and using it to block the coating material, the process ensures the first coating does not contact the distal edge surface, thereby preventing the harmful bimetallic interaction.
2Reliability
If the mask is positioned to prevent first coating contact with the edge, then corrosion is prevented, but the manufacturing complexity increases
Solution Approach 1:
The mask is positioned and secured to the emblem surface before the coating process begins. This preliminary positioning ensures that when the coating material is applied, it cannot contact the distal edge surface. The mask acts as a pre-established barrier that simplifies the coating process while ensuring consistent results.
Solution Approach 2:
The mask replicates the precise boundary geometry of the emblem's distal edge, creating a negative form that perfectly matches the surface to be protected. This copying approach ensures consistent positioning and coating exclusion without requiring complex positioning mechanisms during the actual coating process.
3Reliability
If the back coating wraps around the distal edge surface, then protection against bimetallic corrosion is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The second coating is applied in a direction that wraps around the distal edge surface, utilizing the three-dimensional geometry of the emblem to achieve complete coverage. This dimensional approach ensures the coating extends over the edge and contacts the first element, creating a protective barrier in multiple directions rather than just on flat surfaces.
Solution Approach 2:
The patent employs a composite coating system where the first coating (aluminum) and second coating are applied in sequence to different regions. The second coating material is selected to be compatible with both the first coating and the chrome plating, creating a composite structure that prevents galvanic corrosion while maintaining aesthetic and protective properties.
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 enhances the durability and aesthetic appeal of vehicle emblems by minimizing corrosion, delamination, and contact with contaminants, while maintaining a metallic appearance and preventing bimetallic charge-activated corrosion.
Implementation Method 1
vacuum metalizing a first coating formed from aluminum onto the third surface, wherein the first coating is not disposed on the fifth surface
Implementation Method 2
depositing a back coating onto the first coating and the fifth surface to thereby wrap the back coating around the distal edge surface
Data Source
AI summary
A method of forming an emblem assembly configured for attachment to a vehicle includes positioning a mask adjacent and in contact with a second element so that the mask covers only a selected portion of the second element and does not cover an exposed portion of the second element. The method includes vacuum metalizing a first coating onto only the exposed portion, wherein the first coating has a distal edge surface abutting the mask, and, after vacuum metalizing, removing the mask from the second element to uncover the selected portion. The method includes depositing a back coating onto only the first coating and the selected portion to thereby wrap the back coating around the distal edge surface, and, after depositing, inserting the second element into a first element configured for attachment to the vehicle so that the first coating does not contact the first element to form the assembly.