Vehicle Inner Flock Coating Laser Two-Color Motif Process

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Solution Overview

Problem

Existing flock coating technologies for vehicles lack the ability to create indicative and/or decorative motifs with multiple visually differentiated areas without using additional layers, limiting the range of effects to variations in tone achievable by laser engraving, which is restricted to a single color and heat-induced darkening.

Innovation Solution

A process that uses a laser beam to selectively remove part of the flock layer, revealing the underlying adhesive layer, creating visually and texturally distinct areas on the inner coating, allowing for two-color effects and other properties like photoluminescence without additional layers, while ensuring the adhesive remains intact and protective.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a laser beam is used to engrave motifs on flock coatings, then motifs can be created, but only single-color tone variations are achievable

Engineering Contradiction:

Improvemotif creation capabilityVSAvoidcolor differentiation range

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by creating visually distinct areas through selective laser removal of flock fibers. The adhesive layer beneath different regions has different visual properties (color, photoluminescence), and by removing flock in specific patterns, motifs with multiple visual characteristics are created without needing additional layers.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent achieves color differentiation by utilizing the adhesive layer's inherent visual properties. When the laser removes flock fibers, the adhesive layer is revealed, creating areas with different colors or photoluminescent properties. This allows multi-color motifs without adding color-changing mechanisms to the flock fibers themselves.

Inventive Principle:

Principle #32Color changes

2Adaptability or versatility

If additional layers are used to achieve two-color effects, then color differentiation is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecolor differentiationVSAvoidlayer structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adhesive layer serves multiple functions: it bonds the flock fibers to the support, provides a protective barrier during laser processing, and acts as a visual element for color differentiation in the motif. This multi-functionality eliminates the need for separate color-providing layers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent extracts the color differentiation function from separate layers and integrates it into the adhesive layer. By removing only the flock layer in selective areas through laser action, the adhesive's visual properties are revealed, providing color variation without requiring additional functional layers.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If laser heat is increased to create deeper engraving, then motif depth is improved, but adhesive layer degradation occurs

Engineering Contradiction:

Improveengraving depthVSAvoidadhesive layer integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent controls the laser processing parameters (power, speed, pulse duration) to achieve selective removal of flock fibers without exceeding the temperature threshold that would degrade the adhesive layer. This precise parameter control allows sufficient engraving depth while maintaining adhesive integrity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes the thermal effect of the laser, which could potentially harm the adhesive, by controlling it to selectively remove only the flock layer. The heat is applied at levels sufficient to vaporize or melt the flock fibers but below the degradation point of the adhesive, turning a potential harmful effect into a useful selective removal mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

Enables the creation of complex, visually and tactically differentiated motifs on vehicle interiors using the combination of flock and adhesive layers, providing a triple function of fiber adhesion, color differentiation, and protection, without the need for extra layers, enhancing design and functionality.

Implementation Method 1

performing said indicative and/or decorative motif on said inner coating by the action of a laser light beam on the fibres forming the flock layer, such that it eliminates part of the flock layer due to a temperature increase when aiming a laser light beam on said flock layer

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS8974866B2Process for manufacturing an inner flocked coating for vehicles with a two-colour effect

Publication Date: 2015.03.10 GRP ANTOLIN ING SA

AI summary

This invention relates to a process for the manufacture of an inner flock coating for vehicles with an indicative and/or decorative motif, which inner flock coating is made up of a support, an adhesive layer and a flock layer made up of a set of fibers adhered to the support via the adhesive layer, wherein said motif is located on a visible surface of said inner coating and wherein said motif is performed by the combination of at least two visibly different areas of the coating, a first area and a second area on which a laser beam is applied.