Laser Marking Polymer Workpiece for Vehicle Panes
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Solution Overview
Problem
Existing methods for marking plastic vehicle panes, such as injection molding, engraving, and laser marking, face issues with image sharpness, coating distribution problems, and vulnerability of marks to mechanical and chemical damage, especially when applied after lacquer coating, and visibility concerns when placed in the transparent visual field.
Innovation Solution
A laser-marked polymer workpiece is produced by multi-component injection molding, where a mark is introduced through the transparent component into the opaque component using a laser, creating a local brightening effect that is protected from environmental influences and does not interfere with the transparent visual field, and is applied before the lacquer coating to avoid coating distribution issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mark is introduced by injection molding as a relief, then the mark can be applied to the pane, but image sharpness, contrast, minimum font size, and level of detail are limited
Solution Approach 1:
The patent replaces the mechanical injection molding relief process with a laser marking system that uses optical energy to create marks directly on the polymer surface. This substitution enables high-resolution marking with superior image sharpness, contrast, and detail while avoiding the manufacturing limitations of mechanical relief processes
Solution Approach 2:
The patent changes the marking approach from mechanical relief formation to direct surface modification using laser parameters. By controlling laser power, pulse duration, and scanning speed, the system achieves high-resolution marks with excellent image quality that cannot be obtained through conventional injection molding reliefs
2Manufacturing precision
If a mark is engraved or milled into the pane as a relief after injection molding, then the mark can be applied, but coating distribution problems occur at the time of lacquer coating
Solution Approach 1:
The patent performs laser marking as a preliminary action before lacquer coating, creating the mark on the polymer surface in advance. This timing ensures that subsequent coating processes can proceed uniformly without encountering the distribution problems that arise when marking is done after coating
Solution Approach 2:
The patent replaces mechanical engraving or milling with laser surface marking, which does not create physical reliefs or surface irregularities. This substitution eliminates the coating distribution problems that occur with mechanical marking methods while still achieving durable mark application
3Ease of manufacture
If laser marking is applied to darken a region of the surface, then the mark can be created, but the mark is not protected against mechanical and chemical damage and UV radiation
Solution Approach 1:
The patent performs laser marking as a preliminary action before applying protective lacquer coating. The mark is created first, then the protective coating is applied over the entire surface, providing mechanical, chemical, and UV protection to both the polymer and the embedded mark
Solution Approach 2:
The patent embeds the laser mark within the polymer structure and then nests the protective lacquer coating over the mark. This layered structure protects the mark from mechanical and chemical damage while the transparent coating preserves visibility
4Loss of information
If the mark is applied in the transparent visual field of the pane, then the mark is visible, but it has a disturbing effect on the visual field
Solution Approach 1:
The patent applies local quality by positioning the mark exclusively in the opaque component region of the pane. This location choice ensures the mark is visible and readable while avoiding the transparent visual field, thus eliminating any disturbing effect on the viewer's perception
5Ease of manufacture
If laser sensitive materials are introduced into the workpiece to enable laser marking, then laser marking can be achieved, but the production of the workpieces is rendered more difficult
Solution Approach 1:
The patent utilizes the inherent properties of the polymer materials already present in the workpiece to enable laser marking. The polymer's natural interaction with laser energy provides the marking capability without requiring additional laser-sensitive materials, thus avoiding increased production complexity
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 provides a durable and visually non-disruptive mark that is protected from mechanical and chemical damage, avoids coating distribution problems, and maintains the transparency of the pane, making it suitable for use in motor vehicle components without compromising the lacquer layer or visibility.
Implementation Method 1
a mark is introduced with at least one laser through the transparent component into the surface of the opaque component facing the transparent component
Implementation Method 2
the opaque component is irradiated through the transparent component with at least one laser
Data Source
AI summary
A laser-marked polymer workpiece is described. The workpiece has a transparent component and an opaque component applied to at least one region of the transparent component. A mark is introduced onto a surface of the opaque component facing the transparent component with at least one laser. The mark is introduced, via a laser, through the transparent component. The mark is a lightening of the surface of the opaque component on which the mark was introduced.