Injection Molded Window With Localized Scratch-Resistant Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing motor vehicle windows with scratch-resistant coatings require excessive post-processing, increasing costs and potentially providing excessive scratch resistance on the interior surfaces.
Innovation Solution
An injection molded window with a scratch-resistant film on the interior and a scratch-resistant coating on the exterior, both integrated in a single mold process, using a transparent or translucent plastic substrate and a scratch-resistant layer that cures during molding, along with optional decorative and functional layers, and an adhesive for bonding the film to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-process treatments (spraying and UV curing) are applied to both sides of the window, then scratch resistance is provided, but manufacturing cost increases and interior scratch resistance may be excessive
Solution Approach 1:
The patent applies different scratch-resistant treatments to different surfaces of the window: a scratch-resistant coating is applied only to the exterior surface, while the interior surface receives no coating. This local differentiation provides appropriate scratch resistance where needed (exterior) while avoiding excessive protection on the interior, thereby reducing manufacturing costs and eliminating unnecessary post-processing steps.
2Reliability
If post-process treatments are applied to both interior and exterior surfaces, then both surfaces are protected, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The invention implements local quality by restricting the scratch-resistant coating application to only the exterior surface of the window. This eliminates the need for separate post-processing steps on the interior surface, thereby simplifying the manufacturing process, reducing production time, and improving overall manufacturing efficiency while still providing adequate scratch protection where it is most needed.
3Reliability
If a scratch-resistant coating is applied to the interior surface, then interior scratch resistance is improved, but it may provide excessive protection that is not needed
Solution Approach 1:
The patent applies local quality principles by determining that the interior surface of the window does not require scratch-resistant coating. Instead of uniformly coating both surfaces, the invention selectively applies the coating only to the exterior surface, thereby avoiding excessive protection on the interior while simplifying the manufacturing process and reducing costs.
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 reduces post-processing costs and ensures appropriate scratch resistance for both interior and exterior surfaces while maintaining transparency and functionality, enhancing the efficiency and cost-effectiveness of the window manufacturing process.
Implementation Method 1
the scratch-resistant acrylic is UV cured
Implementation Method 2
These parts are formed by forcing or injecting a viscous material, such as a thermoplastic or thermosetting polymer, into a mold or cavity having the desired shape of the part. Thermoplastics are generally injected under elevated temperatures
Data Source
AI summary
An injection molded part for a motor vehicle includes a film having a scratch-resistant layer, a plastic substrate molded to the film, wherein the plastic substrate is at least partially transparent or translucent, and a scratch-resistant coating molded to the plastic substrate on a side opposite the film.