PVD Coating Stack for Backlit Automotive Color Etching
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Solution Overview
Problem
Current automotive finishes, particularly those used in backlit applications, face challenges in maintaining transmissibility of light due to the pigments in top-coatings, which can hinder the backlit effect.
Innovation Solution
The proposed solution involves a multi-layered finish comprising a tinted primer, a semi-transparent metallic coating, and a top-coat applied over a polymer substrate. The tinted primer and semi-transparent metallic coating define discontinuities that are filled by the top-coat, allowing for color alteration without compromising light transmissibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a top-coat with pigments is applied over the vapor deposited coating, then color alteration is achieved, but light transmissibility is reduced and the backlit effect is hindered
Solution Approach 1:
The coating system is segmented into distinct functional layers: a vapor deposited coating layer for color development and light transmission, and a separate top-coat layer for color alteration and protection. This segmentation allows each layer to perform its specific function optimally without interfering with the other's primary purpose.
Solution Approach 2:
The top-coat is applied selectively to specific regions or patterns on the vapor deposited coating rather than uniformly covering the entire surface. This localized application allows color alteration in designated areas while preserving light transmissibility in other regions, maintaining the backlit effect where required.
2Ease of manufacture
If the top-coat thickness is increased to improve color saturation, then color intensity is enhanced, but light transmissibility through the top-coat decreases
Solution Approach 1:
The top-coat is applied with controlled thickness that provides sufficient color saturation for aesthetic purposes while remaining thin enough to allow light transmission. The coating thickness is optimized to achieve the desired color intensity without completely blocking light, applying just enough pigment to achieve the visual effect while preserving the backlit functionality.
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 effectively alters the color of automotive components while maintaining the backlit effect, ensuring that light can pass through the finish without significant interruption, even in etched regions.
Implementation Method 1
Physical vapor deposition is one technique for forming a finish on various substrates, including polymer substrates. During physical vapor deposition a source material is evaporated and deposited on the substrate surfaces to form a vapor deposited coating.
Implementation Method 2
The pigments in the top-coating may affect the transmissibility of light through the top-coating and hinder the use of the coated substrates in backlit applications.
Data Source
AI summary
The present disclosure is directed to an automotive component and method of finishing such component including a polymer substrate, a tinted primer disposed over a first surface of the polymer substrate, a semi-transparent metallic coating disposed over the tinted primer. The semi-transparent metallic coating and tinted primer define at least one discontinuity. The automotive component further includes a top-coat disposed over the semi-transparent metallic coating and fills in the discontinuity. In aspects, the automotive component is back-lit and includes a light emitting source optically coupled to a second surface of the polymer substrate.