Transparent Vehicle Part Coating With Laser-Etched Paint Patterns

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Solution Overview

Problem

Existing methods for enhancing the appearance of transparent vehicle parts, such as headlights, face challenges with color matching issues and lack of precision in pattern application, which affect the aesthetics and functionality of the vehicle.

Innovation Solution

A method involving the application of a first and second varnish layer followed by a paint layer, with laser radiation used to engrave the paint and varnish in a predefined pattern, allowing for precise removal and ensuring color matching with the vehicle's paint, while protecting the part from ultraviolet radiation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a film with predefined opaque pattern is overmoulded onto the external surface of the transparent part, then the appearance of the light beam is improved, but color matching problems with the vehicle paint occur

Engineering Contradiction:

Improvepattern precisionVSAvoidcolor matching

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention changes the material parameter from film to paint, allowing the coating material to match the vehicle's paint color while maintaining the ability to create precise patterns through laser etching of the varnish layer

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical overmoulding process with a combination of painting and laser etching, where laser radiation selectively removes varnish and paint to create the desired pattern, achieving both precision and color matching

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If painting and marouflage are used to decorate the transparent part, then color matching with vehicle paint is achieved, but the pattern precision is insufficient

Engineering Contradiction:

Improvecolor matchingVSAvoidpattern precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention introduces a varnish layer as an intermediary between the transparent part and the paint layer. This varnish layer serves as a sacrificial mask that can be precisely removed by laser etching, enabling high-precision pattern creation while maintaining good color matching with the vehicle paint

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces conventional mechanical etching methods with laser radiation, which provides superior precision in pattern creation while working effectively with the paint and varnish layers

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the transparent part made of polycarbonate is directly treated, then the process is simplified, but ultraviolet radiation damage occurs and adhesion problems arise

Engineering Contradiction:

Improveprocess complexityVSAvoidultraviolet radiation damage

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The invention applies a first varnish layer directly to the polycarbonate part before painting. This preliminary action protects the polycarbonate from ultraviolet radiation and creates a proper surface for subsequent paint adhesion, preventing both UV damage and adhesion problems

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention creates a composite structure with multiple layers (first varnish layer, paint layer, second varnish layer) that combines the protective properties of varnish with the aesthetic properties of paint, while protecting the underlying polycarbonate from UV radiation

Inventive Principle:

Principle #40Composite materials

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 method provides improved precision and color matching, enhancing the appearance and functionality of transparent vehicle parts by allowing for precise pattern engraving and UV protection, thus improving the overall quality and aesthetics of the vehicle's exterior lighting.

Implementation Method 1

the layer of paint and the second layer of varnish are partially irradiated with laser radiation so as to etch the layer of paint and the second layer of varnish

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

The first and second layers of varnish can be made of a material that absorbs or reflects ultraviolet radiation. This protects the transparent part from ultraviolet radiation which could damage it by photodegradation

Methodology Applied

Scientific EffectUV absorption: Absorption (EM radiation)

Implementation Method 3

the first and second layers of varnish are transparent to any laser radiation having a wavelength in the near infrared

Methodology Applied

Scientific EffectInfrared transmission: Infrared Radiation

Data Source

PatentEP3772380B1Method for manufacturing a transparent vehicle part

Publication Date: 2024.09.04 OPMOBILITY SE

Figure 1~2

AI summary

In this process for manufacturing a vehicle part (2), the following steps are implemented: - application of a first layer of varnish (6) on a transparent part (4), - application of a layer of paint (7) on the first layer of varnish (6), - application of a second layer of varnish (12) on the layer of paint (7), and - partial irradiation of the layer of paint (7) and the second layer of varnish (12) with laser radiation (14).