Laser-Etched Vehicle Part Coating Without Sticker Effect
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Solution Overview
Problem
The existing methods for manufacturing vehicle parts with multilayer paint coatings result in a 'sticker' effect due to thickness differences, increased manufacturing time, and cost, and are not suitable for all types of vehicle parts, particularly body parts.
Innovation Solution
A method involving a single layer of industrial lacquer applied to a plastic part, which is then partially irradiated with laser radiation to create a pattern, reducing the thickness and eliminating the need for a varnish layer, thereby simplifying the process and minimizing the 'sticker' effect while maintaining aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multilayer paint system (primer, base coat, clear coat) is applied to achieve adequate protection and coloration, then the protective and aesthetic functions are fulfilled, but the total coating thickness increases to 60-80 μm, creating a sticker effect and increasing manufacturing complexity
Solution Approach 1:
The patent combines the functions of primer, base coat, and clear coat into a single lacquer layer. This lacquer layer simultaneously provides adhesion (primer function), coloration (base coat function), and protection (clear coat function), reducing the total coating thickness from 60-80 μm to approximately 20 μm while eliminating the sticker effect at pattern edges.
2Reliability
If three separate paint layers are applied one after another to fulfill protective and aesthetic functions, then adequate protection and coloration are achieved, but the manufacturing time and production cost increase
Solution Approach 1:
The patent merges three separate painting operations into a single lacquer application step. This single layer is applied once and then laser-etched to create the desired pattern, eliminating the need for sequential application of primer, base coat, and clear coat, thereby significantly reducing manufacturing time and production cost.
3Reliability
If a varnish layer is added to the multilayer paint system to enhance protection, then the protective function is improved, but the coating thickness increases further and laser engraving becomes more difficult without damaging the underlying part
Solution Approach 1:
The patent eliminates the separate varnish layer by incorporating its protective functions into the single lacquer layer. The lacquer is formulated to provide adequate protection on its own, and its composition is optimized for laser etching, allowing clean pattern creation without damaging the underlying plastic part.
Solution Approach 2:
The patent changes the chemical composition and physical properties of the coating material to create a single lacquer layer that is specifically optimized for laser processing. This lacquer has parameters (thickness, composition, curing characteristics) that are tailored to enable precise laser etching while providing sufficient protection, replacing the multilayer system that was difficult to engrave.
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 visually appealing, customized appearance with reduced thickness, eliminating the 'sticker' effect and simplifying the manufacturing process, while ensuring the lacquer layer provides adequate protection and coloration, suitable for various vehicle parts.
Implementation Method 1
partially irradiating the layer of lacquer with laser radiation so as to etch the layer of lacquer
Data Source
Figure 1~4
AI summary
This process for manufacturing a vehicle part (2) includes the following steps: - application of a layer of lacquer (6) onto a plastic part (4), the layer of lacquer (6) having a different visual appearance from that of the plastic part (4), and - partial irradiation of the layer of lacquer (6) with laser radiation (8) so as to etch the layer of lacquer (6).