Laser Graining Mold Cavities for Bodywork Parts
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Solution Overview
Problem
Existing methods for creating bodywork parts with accentuated optical effects and controlled dullness are not precise enough, particularly for small areas, and are inefficient in masking unmodified zones, leading to increased cycle times and risk of defects.
Innovation Solution
A process involving laser graining on mold cavities to produce shallow, precise bosses that create depressions extending vertically or horizontally, allowing for precise control over optical effects and surface texture, reducing the need for excessive reliefs and minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional graining methods (chemical attack, sandblasting, bead projection) are used to modify surface finish, then large areas can be treated, but precision is insufficient for small areas and masking becomes difficult
Solution Approach 1:
The patent replaces traditional mechanical graining methods (sandblasting, bead projection) with laser graining technology. The laser beam precisely modifies the mold cavity surface to create bosses with controlled dimensions and orientation, eliminating the need for masking and enabling high-precision treatment of small areas while maintaining ease of manufacture.
2Illumination intensity
If large reliefs and depressions are created in the mold to achieve accentuated optical effects, then optical effect is enhanced, but cycle times increase and risk of surface defects increases
Solution Approach 1:
The patent changes the parameters of the mold surface modification by creating shallow bosses with specific orientation (vertical and/or horizontal extensions) rather than deep reliefs. The laser graining process allows precise control of boss depth and dimensions, achieving accentuated optical effects through orientation-controlled light reflection while maintaining short injection cycles and avoiding surface defects.
3Manufacturing precision
If traditional graining methods are used, then surface treatment can be applied, but the ability to create regular repeating patterns with high precision is limited
Solution Approach 1:
The patent replaces complex mechanical masking and selective treatment systems with a laser graining system that can directly write precise patterns on the mold surface. The laser technology enables regular repeating patterns with high precision through programmable motion control, simplifying the overall process while achieving superior pattern accuracy.
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 production of bodywork parts with accentuated or reduced depth impressions and dullness effects, improving precision and reducing cycle times while minimizing defects, by using laser graining to create shallow but precise bosses on the mold surface.
Implementation Method 1
at least one boss is produced by laser graining on the surface of the mold cavity
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method of modifying a mold cavity (2) for body parts (6), in which at least one boss (12) is made by laser graining on the surface of the mold cavity, the boss (12) being arranged to obtain a body part (6) comprising a depression (14) extending at least partly vertically and/or horizontally when the body part (6) is mounted on a motor vehicle.