Structured Plastic Vehicle Parts via Non-Melting Particles
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Solution Overview
Problem
Existing vehicle add-on parts made of plastic often have smooth, homogeneous surfaces that are sensitive to scratches and dirt, and do not seamlessly integrate with painted body parts, leading to unsightly transitions and limited suitability for applications requiring a smooth, chrome-like appearance.
Innovation Solution
A plastic element with a structured surface is created by adding non-melting particles to the extruded part, which are then imaged by a paint film, or by mechanically structuring the surface using devices like grain rollers or spray nozzles, to produce a surface similar to an orange peel finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a smooth and homogeneous surface is used for the plastic element, then it can provide a chrome-like appearance, but it becomes susceptible to scratches and dirt that are immediately visible
Solution Approach 1:
The patent applies a structured surface only to specific areas of the plastic element where it contacts or is near painted body panels, while other areas can remain smooth. This localized structuring provides the necessary durability and visual integration without compromising the overall aesthetic appearance of the entire component.
Solution Approach 2:
The patent changes the surface parameter from completely smooth to structured with specific patterns (such as orange peel, grain, or other textures). This parameter change increases the surface's resistance to showing scratches and dirt while maintaining visual compatibility with painted surfaces through controlled texturing.
2Shape
If a smooth and homogeneous surface is used for the plastic element, then it can provide a chrome-like appearance, but it creates a visible and disruptive transition to painted body panels
Solution Approach 1:
The patent applies a structured surface only to specific areas of the plastic element where it contacts or is near painted body panels, while other areas can remain smooth. This localized structuring provides the necessary durability and visual integration without compromising the overall aesthetic appearance of the entire component.
Solution Approach 2:
The patent uses surface structuring to change the optical properties of the plastic element, creating light scattering effects that match the appearance of painted surfaces. This allows the plastic element to visually blend with painted body panels by replicating the diffuse reflector characteristics of painted surfaces.
3Reliability
If particles are added to the plastic material to create surface structure, then the surface durability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines the structuring function with the existing extrusion or injection molding process by incorporating particles into the plastic material before forming. This merging of the structuring step into the base manufacturing process avoids adding separate complex structuring equipment while still achieving the desired surface durability and appearance.
Solution Approach 2:
The patent prepares the surface structure in advance by mixing particles into the plastic material before the forming process. This preliminary action ensures that the structuring is already embedded in the material, eliminating the need for subsequent complex surface treatment steps and simplifying the overall manufacturing 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
The structured surface of the plastic element enhances its durability and aesthetic integration with painted body parts, providing a finish that is both resistant to scratches and visually cohesive with painted surfaces.
Implementation Method 1
adding non-melting or minimally melting particles to the extruded part, which provide the extruded part with a surface structure that can subsequently be replicated by a coating film applied to the extruded part
Implementation Method 2
the structuring can be reproduced by the subsequently applied lacquer film
Implementation Method 3
structuring the surface of the plastic element coated with the lacquer film, for example, using at least one texture roller, a sprinkler unit, and/or a spray nozzle unit
Data Source
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AI summary
The present invention relates to a plastic element for a vehicle, wherein the plastic element is designed as an extrusion part or as an extrusion part with a base, wherein at least one section of the outside of the extrusion part is coated with a lacquer film to form the plastic element with a structured surface, wherein the structured surface preferably has a structure as similar as possible to a painted surface, wherein the extrusion part is made of a plastic material or a mixture of a plastic material and particles, wherein the particles are made of a material which does not melt or melts as little as possible with the plastic material to form a structured surface of the extrusion part, wherein, to form the structured surface of the plastic element, the lacquer film replicates the surface of the extrusion part structured by the added particles.