Vehicle Outer Trim Masking Layer Integrated With In-Mold Laser Structuring
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Solution Overview
Problem
Existing methods for producing partially translucent vehicle exterior trim parts with masking layers are time-consuming and costly due to separate processing steps after injection molding.
Innovation Solution
Integrate the application of the masking layer and laser processing directly within the injection molding process, using transparent polymers and high-energy laser radiation to structure or perforate the layer, combined with inkjet printing or other coating methods, and optionally sealing with polyurea or polyurethane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the masking layer is applied after injection molding in separate processing steps, then the component can be properly manufactured with masking layer, but the production time and cost increase
Solution Approach 1:
The patent combines multiple separate processing steps (injection molding, masking layer application, and laser structuring) into a single integrated process. The masking layer is applied to the base component while it remains in the mold, and laser structuring is performed before demolding, eliminating the need for separate handling and processing steps that would otherwise require additional time and equipment.
Solution Approach 2:
The masking layer is applied to the base component while it is still in the mold cavity, before the component is removed. This preliminary action allows subsequent laser structuring to be performed on the masked component without requiring additional handling or positioning steps, thereby reducing overall production time.
2Manufacturing precision
If additional separate processing steps are used for masking layer application and structuring, then the masking layer can be properly applied and structured, but the production cost increases
Solution Approach 1:
The patent merges the masking layer application process with the injection molding process by applying the masking layer to the base component while it remains in the mold. This integration eliminates the need for separate handling, positioning, and processing equipment that would otherwise be required, thereby reducing production costs while maintaining precision through controlled application conditions.
3Ease of operation
If the base component is removed from the mold before masking layer application, then the masking layer can be applied, but handling time and complexity increase
Solution Approach 1:
The masking layer is applied to the base component while it is still in the mold cavity, before the component is removed for final processing. This preliminary action eliminates the need for additional handling and positioning steps that would otherwise be required, thereby reducing handling time and operational complexity.
Solution Approach 2:
The injection mold itself serves as the substrate for masking layer application. The base component remains in its molded position and the masking layer is applied directly to it without requiring removal or repositioning, allowing the molding process to serve multiple functions (forming and masking preparation) simultaneously.
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
Facilitates faster and more cost-effective production of exterior trim parts by integrating masking layer application and laser processing within the injection molding process, reducing time and costs.
Implementation Method 1
structuring or perforating or partially removing the masking layer (1) by means of high-energy laser radiation (L)
Data Source
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AI summary
The invention relates to a method for producing a partially translucent exterior trim part for a vehicle, said exterior trim part having at least one masking layer (1), wherein the masking layer (1) is applied to a thin-walled base component (2) at least partially defining the geometry of the exterior trim part, wherein the base component (2) has an outer side (A) that is visible in its intended use and a rear side opposite the outer side (A), wherein the base component (2) is primary formed in an injection molding tool (3) by means of an injection molding process, wherein the injection molding tool (3) has at least two mold halves (3a, 3b) that, in the closed state, form a cavity (4) defining the base component (2) between them, wherein the method comprises the following sequence of steps: primary forming of the base component (2) by introducing at least one plastic material (K) forming the base component (2) into the cavity (4),wherein the at least one plastic material comprises a transparent or translucent polymer material, in particular polycarbonate (PC), or polypropylene (PP) or polymethyl methacrylate (PMMA) or acrylonitrile-butadiene-styrene copolymer (ABS) or polycarbonate-acrylonitrile-butadiene-styrene copolymers (PC-ABS copolymers), solidifying the plastic material (K), partially or completely opening the tool halves (3a, 3b) so that at least a partial area (5) of the surface of the primary molded base component (2) becomes freely accessible, wherein the base component (2) is further fixed in position by at least one of the tool mold halves (3a) and/or by at least one ejector integrated in at least one of the tool mold halves (3a), applying the masking layer (1) to the partial area (5) of the base component (2) by means of a coating process, while the base component (2) remains in or on the tool mold half (3a) is fixed in position,Structuring or perforating or partially removing the masking layer (1) by means of high-energy laser radiation (L), while the base component remains fixed in position in or on the mold half (3a), complete demolding and removal of the base component (2) from the injection molding tool (3).