Splat Polymer Coating for Exterior Trim Anti-Icing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fibrous exterior trim parts for motor vehicles face issues with icing, soiling, and stone chipping due to their open structure, which compromises noise absorption and increases weight, leading to potential damage and fuel consumption.
Innovation Solution
A fibrous exterior trim part with a splat polymer coating applied via thermal spraying, which enhances anti-icing and anti-soiling properties while maintaining air permeability for noise attenuation, and can be tailored for specific areas of the part to improve stiffness and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a fibrous carrier structure is used for exterior trim parts, then weight is reduced and noise attenuation is improved, but resistance to icing and soiling deteriorates
Solution Approach 1:
The invention applies a polymeric coating layer on top of the fibrous carrier material, creating a composite structure that combines the lightweight, noise-absorbing properties of the fibrous material with the protective, anti-icing, and anti-soiling properties of the polymeric coating
Solution Approach 2:
A thin polymeric coating layer is applied over the fibrous carrier, forming a protective film that prevents ice and soil adhesion while maintaining the underlying fibrous structure's acoustic attenuation capabilities
2Reliability
If a closed or perforated film is laminated on the surface to prevent fouling and icing, then resistance to icing and soiling is improved, but noise absorption deteriorates
Solution Approach 1:
The polymeric coating is applied in a controlled manner to maintain air permeability, allowing sound waves to penetrate through the coating and be absorbed by the underlying fibrous carrier material while still providing protective functions
Solution Approach 2:
The coating is applied selectively to specific areas of the fibrous carrier, such as the outer surface exposed to road debris and ice, while maintaining the porous structure in areas where noise absorption is critical
3Reliability
If additional impregnated fibrous layers or resin extruded layers are applied to prevent fouling and icing, then resistance to icing and soiling is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention changes the physical state and application method of the polymeric material, applying it as a coating rather than through complex impregnation or extrusion processes, simplifying manufacturing while achieving the desired protective properties
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 splat polymer coating significantly increases the resistance to icing, soiling, and stone chipping, while maintaining noise absorption and durability, and can be adjusted for airflow resistance and thickness to suit different areas of the part.
Implementation Method 1
a thermal spray process, for instance a combustion or plasma based spray process, is used whereby a fluid flows to accelerate and melt and or soften the polymer powder particles in-flight
Implementation Method 2
Upon impact at the surface of the targeted material, the heated particles (droplets) deform (splat), consolidate and cool (solidify) to form a coating or a deposit of material
Implementation Method 3
For additional acoustic attenuation of tire and road noise absorbing materials are used either in combination with an injection moulded carrier or as a stand-alone solution forming a stiff enough part
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An exterior trim part comprising at least a fibrous layer forming the carrier, characterised in that at least one surface consists of a splat polymer coating deposited at least along a portion of the surface forming a splat polymer coating layer.