Laser-Patterned Polymer Vehicle Components Without Paint Layers
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Solution Overview
Problem
Existing vehicle components, particularly in the premium segment, face challenges in achieving high-quality, sustainable designs without the use of paint layers, which are costly, environmentally harmful, and limit recyclability.
Innovation Solution
A vehicle component made from a polymer compound containing laser-sensitive pigments that change color upon high-energy radiation, creating stone or terrazzo-like patterns, eliminating the need for paint layers and enhancing recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If paint layers are used to achieve high-quality surface finish and design options, then surface appearance and protection are improved, but manufacturing cost, energy consumption, and environmental impact increase
Solution Approach 1:
The patent uses laser-sensitive pigments embedded in the polymer compound that change color when irradiated with laser radiation. This allows the creation of stone patterns and terrazzo-like patterns directly in the plastic material without requiring separate paint layers. The color change effect is achieved through the chemical transformation of the pigments under laser irradiation, providing both design flexibility and surface protection in a single integrated component.
Solution Approach 2:
The patent employs a polymer compound containing laser-sensitive pigments as a composite material system. This composite integrates the structural polymer matrix with functional pigments that respond to laser irradiation, creating a multi-functional material that provides both structural integrity and aesthetic design capabilities without requiring additional paint layers or protective coatings.
2Shape
If multiple materials including paint layers are used to achieve design options, then surface appearance is improved, but recyclability and material simplicity worsen
Solution Approach 1:
The patent merges the functions of structural material, colorant, and pattern creation into a single integrated polymer compound system. The laser-sensitive pigments are incorporated directly into the polymer matrix during compounding, eliminating the need for separate paint layers and protective coatings. This unified approach maintains design flexibility while significantly improving recyclability by reducing material complexity and the number of different substances required.
3Object-generated harmful factors
If laser marking is used to create patterns, then emission-free production is achieved, but previously applied paint layers must be removed which adds complexity
Solution Approach 1:
The patent applies preliminary action by incorporating laser-sensitive pigments into the polymer compound before shaping and processing. This pre-integration of functional pigments eliminates the need for subsequent paint layer removal steps. When laser irradiation is applied to create patterns, the pigments respond directly without requiring the removal of existing paint layers, thereby simplifying the overall process while maintaining emission-free production characteristics.
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 approach provides a high-quality, sustainable surface finish with reduced material usage and emissions, offering design flexibility and improved recyclability, while minimizing the need for protective coatings.
Implementation Method 1
A vehicle component, having a shaped body formed from a polymer compound including laser-sensitive pigments, in which a portion of the laser-sensitive pigments has been modified by irradiation with high-energy radiation such that the irradiated laser-sensitive pigments have a color change compared to the non-irradiated laser-sensitive pigments
Data Source
AI summary
A vehicle component for a motor vehicle with a moulding made of a polymer compound which contains laser-sensitive pigments and in which some of the laser-sensitive pigments are altered by irradiation with high-energy radiation, such that the irradiated laser-sensitive pigments undergo a change in colour in comparison with the non-irradiated laser-sensitive pigments. The irradiation with high-energy radiation takes place in such a way that the surface of the moulding has a stone patterning or terrazzo-like patterning. A motor vehicle with such a vehicle component and a production method are also specified.