Laser Marking Metal Surface Element on Plastic Base Body
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Solution Overview
Problem
Existing methods for producing components with symbols for motor vehicles or household appliances are costly and complex, requiring expensive tools and processes such as stamping and electroplating, which can lead to defects and non-compliance with symbol standards.
Innovation Solution
A method where a symbol is introduced into a metal surface element using a laser after it has been provided with a plastic base body through deep-drawing and back-injection, eliminating the need for additional tools and allowing for uniform production with subsequent individualization, and enabling the creation of a stable, real metal surface component with enhanced durability and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional stamping and electroplating processes are used to produce components with symbols, then symbols can be created on metal surface elements, but production costs and process complexity increase significantly
Solution Approach 1:
The patent replaces conventional mechanical stamping processes with laser technology for symbol production. The laser beam directly etches symbols onto the metal surface element after back-injection, eliminating the need for complex stamping tools and electroplating processes. This substitution reduces device complexity while maintaining symbol quality through precise laser control.
Solution Approach 2:
The patent performs the back-injection of the plastic base body onto the metal surface element before introducing the symbol with the laser. This preliminary action stabilizes the surface element, preventing deformation during laser processing and enabling direct symbol creation without complex tooling. The sequence is: deep-drawing of surface element → back-injection of base body → laser symbol introduction.
2Productivity
If stamping tools are used to create symbols on surface elements, then symbols can be produced, but expensive tools and additional processing steps are required
Solution Approach 1:
The patent replaces expensive mechanical stamping tools with a laser beam system. The laser directly etches symbols onto the metal surface element after back-injection, eliminating tooling costs and reducing the number of processing steps. This reduces manufacturing cost while maintaining or improving productivity through direct digital fabrication.
Solution Approach 2:
The patent extracts the symbol creation step from the conventional stamping process and performs it separately with a laser after back-injection. This separation eliminates the need for complex multi-step stamping tools and allows for simpler, more cost-effective production. The symbol is introduced as a post-processing step rather than an integrated tooling operation.
3Reliability
If symbols are introduced before back-injection, then the surface element can be individually marked, but the element lacks stability during processing
Solution Approach 1:
The patent performs back-injection of the plastic base body onto the metal surface element before introducing the symbol with the laser. This preliminary action provides structural stability to the surface element, preventing deformation during laser processing. The stable assembly allows for precise symbol creation while maintaining the ability to customize different symbols on different components.
4Manufacturing precision
If conventional methods are used to produce components with symbols, then metal surface elements can be manufactured, but additional tools and processes are required increasing complexity
Solution Approach 1:
The patent replaces complex mechanical stamping and electroplating systems with a laser beam system for symbol creation. The laser directly etches accurate symbols onto the metal surface element after back-injection, eliminating the need for multiple specialized tools and processes. This simplifies production while maintaining high symbol accuracy through precise laser control and positioning.
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 production costs and complexity, ensures reliable manufacturing, and allows for high-quality, easily recognizable symbols that can be illuminated, maintaining a genuine metal surface while being resistant to contamination and abrasion.
Implementation Method 1
the symbol is introduced into the surface element by means of a laser only after the surface element has been provided with the base body. The surface element is formed in a deep-drawing process and provided with the base body by back-injection, wherein the back-injection takes place after the deep-drawing process without changing tools
Data Source
Figure 1
AI summary
The invention relates to a method for producing a component (10) comprising a symbol (16) for a motor vehicle, in which a symbol (16) is incorporated into a surface element (12) consisting of a metal material, and in which the surface element (12) is provided with a base body (14) consisting of a plastic, the symbol (16) only being incorporated into the surface element (12) by means of a laser once the surface element (12) has been provided with the base body (14). The invention also relates to a component (10) for a motor vehicle. The invention further relates to a method for producing a component for a household appliance and to a component (10) for a household appliance.