Tailored Metal Surface Textures for Forming and Paint Adhesion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing metal substrates with uniform textures are not optimally tailored to specific surface areas, leading to suboptimal performance in areas requiring different surface properties for appearance, adhesion, tribological, and forming operations, especially in the automotive industry.

Innovation Solution

A metal substrate with tailored surface textures applied using laser texturing, allowing for varied texture patterns over predefined areas to match specific surface properties, such as paint, visual appearance, friction, and forming requirements, by adjusting dimple size, density, and positioning based on product-specific data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a uniform texture is applied over the entire metal substrate surface using temper rolling, then the manufacturing process is simple and efficient, but the surface properties cannot be optimized for different functional areas of the final product

Engineering Contradiction:

Improvesurface property optimization for different areasVSAvoidtexturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The metal substrate surface is divided into multiple predefined areas, each receiving a different texture pattern tailored to specific functional requirements. The laser texturing system applies textures selectively to different zones (e.g., high elongation areas, low elongation areas, visible surfaces) rather than uniformly across the entire surface, enabling localized optimization of surface properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different texture patterns with specific characteristics (dimple size, density, depth) are applied to different locations on the metal substrate based on the functional requirements of each area. For example, areas requiring high paint adherence receive textures with specific roughness parameters, while areas requiring low friction receive different texture patterns, achieving local quality optimization.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If different texture patterns are applied over predefined surface areas using laser texturing, then surface properties are optimized for specific areas, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvesurface texture precisionVSAvoidtexturing process ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The traditional mechanical temper rolling texturing system is replaced with a laser texturing system. This substitution enables precise control over texture parameters (dimple diameter, depth, density, spacing) and allows for selective application of different texture patterns to different areas of the metal substrate, achieving high manufacturing precision while maintaining process efficiency through non-contact processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Shape

If the metal substrate is deformed into a deformed part, then the product takes its final shape, but the surface texture deforms locally at different elongation rates affecting appearance and function

Engineering Contradiction:

Improveproduct shapeVSAvoidsurface texture uniformity

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The metal substrate is provided with different texture patterns before deformation based on predicted elongation rates for different areas. Areas expected to undergo high elongation receive textures with larger dimple spacing, while areas with low elongation receive textures with smaller spacing. This preliminary tailoring compensates for deformation effects, ensuring uniform texture appearance and functional properties in the final deformed product.

Inventive Principle:

Principle #10Preliminary action

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 enhances product quality by optimizing surface properties across the entire product surface, improving paint adherence, reducing friction variations, and enhancing forming operations without increasing waviness, thus addressing the limitations of uniform textures.

Implementation Method 1

a single laser beam or a plurality of laser beams is directed at the surface of a moving steel strip, and the single laser beam or the plurality of laser beams are controlled to apply a predetermined texture pattern on the surface of the moving steel strip

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11752532B2Metal substrate provided with tailored surface textures and method for applying such textures on metal substrates

Publication Date: 2023.09.12 TATA STEEL NEDERLAND TECH BV

AI summary

A metal substrate provided with surface textures wherein different texture patterns are provided over predefined surface areas of the metal substrate and wherein the different texture patterns are tailored to predefined surface properties of a product which is to be made out of the metal substrate as well as to a method for applying such surface textures on the metal substrate.