Vehicle Outer Skin Film Forming for Integrated Color and Sensor Windows
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Solution Overview
Problem
Existing methods for producing vehicle front panels require multiple processes, leading to high reject rates and increased component costs, while lacking integration of colored components and electromagnetic wave transmission.
Innovation Solution
A method involving thermoforming a film with a color layer, allowing regions for other colors or electromagnetic waves to pass through, and integrating components via adhesive or overmolding, reducing process steps and enabling illumination and sensor functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple successive processes are used to produce front panels with decorative elements and functional coatings, then the visual appearance and functionality are improved, but the overall reject rate and component costs increase
Solution Approach 1:
The patent combines multiple separate processes (injection molding, painting, masking, laser embossing, PVD coating, hardcoat application) into a single integrated thermoforming process. The film is pre-coated with color layers and functional coatings before thermoforming, allowing all decorative and functional features to be applied in one step rather than through multiple successive processes, thereby reducing cumulative reject rates.
Solution Approach 2:
The color layers and functional coatings are applied to the film before the thermoforming process. This preliminary application of coatings allows the film to be formed into its final three-dimensional shape with all decorative and functional features already in place, eliminating the need for subsequent painting and coating steps that would increase reject rates.
2Adaptability or versatility
If multiple successive processes are used for front panel production, then functional features are achieved, but the number of process steps and component costs increase
Solution Approach 1:
The patent integrates multiple functional features (color decoration, radar transparency, light transparency, illumination, sensor integration) into a single thermoforming process step. The film is pre-coated with color layers and functional coatings, allowing all features to be combined in one process rather than requiring separate steps for each function.
Solution Approach 2:
The film serves multiple functions simultaneously: it provides structural form through thermoforming, decorative color through pre-applied color layers, electromagnetic wave transmission through selectively positioned components, and illumination/sensor integration through embedded elements. This multi-functionality is achieved in a single integrated process.
3Manufacturing precision
If traditional multi-step processes are used, then production accuracy is maintained, but production time and cycle times increase
Solution Approach 1:
Color layers and functional coatings are applied to the film before thermoforming, allowing the film to be formed into its final shape with all features already in place. This eliminates subsequent painting and coating steps, significantly reducing production cycle time while maintaining precision through the single-step thermoforming process.
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
Reduces production complexity, lowers reject rates, and integrates colored and functional components with improved visual appearance and functionality.
Implementation Method 1
the film is subjected to a thermoforming process in order to generate the desired three-dimensional form
Data Source
AI summary
A method for producing components of an outer skin of a vehicle with a film, which is back-molded at least from one a front side or rear side with clear plastics material, includes subjecting the film to a thermoforming process in order to generate the desired three-dimensional form. The film is subjected to further steps for preparation of the back-molding, including providing the film at least partially with a color layer. The film includes regions, through which other colors are intended to show through and be visible from the front side, or electromagnetic waves are intended to pass. The film may be punched-out in the regions to define punched-out portion in which components are inserted. The components are attached to the film by adhesive and/or overmolding on the rear side.