Repair Laminate with Pre-Applied Paint Coating for Surface Protection
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Solution Overview
Problem
Existing methods for repairing and protecting object surfaces, such as those on vehicles, are often costly, time-consuming, environmentally unfriendly, and result in unsatisfactory finishes due to issues with color conformity, durability, and visibility of the repair materials.
Innovation Solution
A laminate comprising a thin polymer film with a paint coating and adhesive, which is applied to the object surface to provide a durable, aesthetically pleasing, and inconspicuous protective layer that conforms to the surface, using a specialized die-cutting process to minimize visibility and ensure accurate application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If touch-up pens are used to repair object surfaces, then repair cost is reduced, but surface finishing quality deteriorates due to poor color conformity and visible bumps
Solution Approach 1:
The paint coating is applied to the polymer film before the laminate is applied to the object surface. This preliminary action allows the paint to be precisely applied in a controlled manufacturing environment, ensuring uniform thickness and perfect color matching, rather than attempting to apply paint after the fact with a touch-up pen.
Solution Approach 2:
The polymer film acts as an intermediary carrier that holds the paint coating. This intermediary allows the paint to be transferred uniformly to the object surface when the laminate is applied, eliminating the need for direct manual paint application and the associated quality issues.
2Ease of manufacture
If touch-up pens are used to repair object surfaces, then repair cost is reduced, but repair time increases due to extended drying requirements
Solution Approach 1:
The paint coating is applied and dried in advance during manufacturing, before the laminate is cut and packaged. This eliminates the drying wait time that would otherwise be required after application to the object surface, allowing immediate use of the repaired area.
Solution Approach 2:
The laminate provides its own dried, ready-to-use paint coating that requires no additional drying time after application. The product is self-contained and self-sufficient, eliminating the need for external drying conditions or extended waiting periods.
3Reliability
If thick protective layers are applied to protect damage-prone areas, then protection durability is improved, but aesthetic appearance deteriorates due to visible thickness and yellowing
Solution Approach 1:
A thin polymer film is used instead of thick protective layers. The film provides adequate protection while maintaining aesthetic appearance due to its thinness and flexibility, preventing the yellowing and visibility issues associated with thicker coatings.
Solution Approach 2:
The laminate combines multiple materials (polymer film, paint coating, adhesive) into a composite structure that provides both protection and aesthetic appearance. The polymer film serves as a protective barrier while remaining visually unobtrusive.
4Productivity
If conventional die-cutting with 90-degree angle is used to cut laminates, then cutting speed is improved, but manufacturing precision deteriorates due to material displacement and bulging
Solution Approach 1:
The die cutting angle is changed from the conventional 90 degrees to a reduced angle (e.g., 45 degrees). This parameter change allows the die to cut through the laminate without displacing material sideways, eliminating bulging while maintaining cutting efficiency.
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
The laminate offers swift, safe, and durable protection against damage and corrosion, maintaining the surface's appearance without the need for extensive drying times, and is designed to withstand various environmental stresses.
Implementation Method 1
an adhesive (4) is provided on the rear surface (21)
Implementation Method 2
a paint coating (3) is provided on the front surface (22)
Implementation Method 3
A laminate (1) comprises a polymer film (2), wherein a paint coating (3) is provided on the front surface (22)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates generally to a laminate for repairing and/or protecting an object surface, to a method of producing a laminate for repairing and/or protecting an object surface, a method of applying a laminate to an object surface, a kit of parts comprising such a laminate, and a vehicle comprising such a laminate. More particularly the invention concerns application of the laminates to vehicles, in particular automobiles, bikes and trucks.