Laser-Sintered Decorative Patterns on Metallic Trim
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Solution Overview
Problem
Existing processes for producing interior trim parts with decorative layers fail to create resistant and attractively formable patterns effectively, as they often damage the underlying metallic surface and result in inefficient pattern reproduction and high reject rates.
Innovation Solution
A process involving the formation of cutout configurations in a protective layer on a metallic base body, deposition of sinterable decorative material, laser-sintering within these configurations, and removal of excess material to create a hardened decorative layer with precise patterns, while maintaining the metallic surface's integrity and allowing for easy pattern changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional processes are used to produce decorative layers on interior trim parts, then the decorative pattern can be applied, but the underlying metallic surface is damaged and the pattern reproduction is inefficient with high reject rates
Solution Approach 1:
A protective layer is applied to the metallic base body before the decorative pattern is created. This preliminary protective action prevents damage to the metallic surface during subsequent processing steps, eliminating the need for surface repair or protection measures later in the manufacturing process
Solution Approach 2:
The protective layer serves as an intermediary between the metallic base body and the decorative material. It allows the decorative pattern to be applied and sintered without directly contacting and damaging the metallic surface, while still enabling precise pattern reproduction through controlled material deposition and removal
2Manufacturing precision
If the protective layer is removed completely to create the decorative pattern, then the pattern can be formed, but the metallic surface outside the pattern is exposed and potentially damaged
Solution Approach 1:
The protective layer is selectively removed only in the specific areas where the decorative pattern should appear, rather than being completely removed. This localized removal approach ensures that the metallic surface outside the pattern area remains protected and intact, while still achieving precise pattern reproduction in the exposed areas
3Productivity
If traditional manufacturing processes are used, then production can proceed, but the production time is extended and reject rates are high due to surface damage and pattern reproduction issues
Solution Approach 1:
The process enables continuous operation by eliminating rework and repair steps. The protective layer ensures that the metallic surface remains intact throughout production, allowing parts to move directly through the manufacturing process without interruptions for surface damage assessment or repair, thereby reducing production cycle time and increasing overall productivity
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 process enables the production of highly precise decorative patterns on interior trim parts with minimal rejects, protecting the metallic surface and ensuring the integrity of plastic reinforcement, allowing for quick and easy pattern changes and reduced production waste.
Implementation Method 1
the formation of the cutout configuration in the protective layer defined by a predetermined decorative pattern is produced by vaporisation of the material of the protective layer according to a predetermined pattern
Implementation Method 2
laser-sintering of the intermediate layer inside the cutout configuration defined by the decorative pattern in order to produce at least one hardened portion of the intermediate layer
Data Source
AI summary
A process for producing an interior trim part (1) with a decorative layer situated on a first side (S1) thereof and forming a decorative pattern (M) for the interior of a motor vehicle, the process comprising the following steps:(a) formation of at least one cutout configuration (R), defined by a predetermined decorative pattern (M), in a protective layer (120) situated on a first side (S1), which is situated on a first surface (110a) of the shell-shaped base body (110) made of a metallic material,(b) deposition of sinterable decorative material on the first side (S1) in such a way that the decorative material, as an intermediate layer (150), covers at least the area in which the cutout configuration (R) defined by the decorative pattern (M) is formed in the protective layer (120),(c) laser-sintering of the intermediate layer (150) inside the at least one cutout configuration defined by the decorative pattern (M),(d) removal of the sinterable decorative material that is situated outside the at least one cutout configuration defined by the decorative pattern (M),as well as an interior trim part (1).