Transparent Sheet Composite for Durable 3D Automotive Decoration
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Solution Overview
Problem
Existing methods for creating three-dimensional decorative effects on motor vehicle parts using plastic materials are fragile, easily scratched, and difficult to apply on large surfaces with complex geometries, and they do not produce a real three-dimensional relief but rather a visual effect based on light and colors.
Innovation Solution
A motor vehicle body part comprising a transparent sheet with a local relief on one face and a complementary relief on an internal injected plastic part, where the transparent sheet is preformed to match the external relief without degrading under molding pressures and temperatures, and can be made thicker than traditional films to withstand injection molding conditions, allowing for a real three-dimensional visual effect without altering the external geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin plastic film is used to create a three-dimensional decorative effect, then the decorative effect is achieved, but the film is fragile and scratches easily during cleaning
Solution Approach 1:
The patent combines a transparent thermoplastic sheet with an injected plastic material to create a composite structure. The transparent sheet provides the decorative three-dimensional effect while the injected plastic material reinforces it, creating a durable composite that resists scratching and degradation during cleaning.
Solution Approach 2:
The patent changes the thickness parameter of the transparent sheet from traditional thin film (less than 0.75 mm) to a thicker sheet (greater than 0.75 mm, preferably greater than 2 mm). This parameter change enables the material to withstand molding temperatures and pressures without degrading, while maintaining the decorative effect.
2Ease of manufacture
If a traditional film is used for decoration, then the visual three-dimensional effect is achieved, but the film degrades under injection molding pressures and temperatures
Solution Approach 1:
The patent changes the thickness parameter of the transparent sheet from traditional thin film (less than 0.75 mm) to a thicker sheet (greater than 0.75 mm, preferably greater than 2 mm). This parameter change enables the material to withstand molding temperatures and pressures without degrading, while maintaining the decorative effect.
3Area of stationary object
If overmolding or bonding is used to deposit a film onto large surfaces, then the film can be applied, but it is difficult to achieve precise deposition on surfaces with varying geometries and openings
Solution Approach 1:
The patent applies preliminary action by pre-forming the transparent thermoplastic sheet with the desired three-dimensional decorative relief before the injection molding process. This pre-formed sheet is then placed in the mold and bonded to the injected plastic material, eliminating the difficulties of depositing film onto complex geometries during the molding process itself.
4Strength
If a thicker transparent sheet is used instead of traditional film, then the sheet can withstand molding temperatures and pressures, but the material quantity increases
Solution Approach 1:
The patent changes the thickness parameter of the transparent sheet from traditional thin film (less than 0.75 mm) to a thicker sheet (greater than 0.75 mm, preferably greater than 2 mm). This parameter change enables the material to withstand molding temperatures and pressures without degrading, while maintaining the decorative effect.
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 solution provides a durable, three-dimensional decorative effect that is resistant to external attacks and can be applied to complex geometries without degrading, maintaining the external geometry and wave transparency of the part.
Implementation Method 1
By transparent is understood that the material allows at least one wavelength of the visible spectrum to pass through
Implementation Method 2
the complementary relief of the inner part is visible from the surface of the wall
Data Source
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Figure 3
Figure 4~5
AI summary
The invention relates to a bodywork part made of plastic material for a motor vehicle, comprising a wall formed by an outer section and an inner section, characterised in that: - the outer section comprises a transparent sheet having a face comprising a local raised pattern at the interface of the two sections and another substantially smooth face on the surface of the wall; and - the inner section made of injected plastic material having a face comprising a raised pattern complementary to that of the outer section at the interface of the two sections. The invention also relates to a method for manufacturing a bodywork part made of plastic material for a motor vehicle, comprising a local raised pattern that can be seen through a transparent sheet having a substantially smooth outer surface.