UV-Hardened Paint Mixture for Adjustable Gloss on PVD-Coated Plastics

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Solution Overview

Problem

Existing methods for achieving a metallic appearance on plastic substrates, such as those used in the automotive industry, face challenges with environmental impact and mechanical susceptibility, particularly when exposed to weather and stone chipping, and fail to consistently meet required gloss levels.

Innovation Solution

A method involving a UV-hardened paint coat mixture of glossy and matte paints applied over a PVD metallic layer, with the paint mixture ratio determining the desired gloss level, providing a durable and adjustable metallic finish.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a thin PVD layer is deposited onto a soft undercoat to achieve metallic appearance, then the metallic appearance is achieved, but the coating becomes very susceptible to mechanical influences

Engineering Contradiction:

Improvemetallic appearanceVSAvoidresistance to mechanical influences

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies a multi-layer composite coating structure consisting of a soft undercoat layer followed by a harder topcoat layer. This composite structure combines the aesthetic benefits of the soft undercoat with the mechanical durability of the harder topcoat, resolving the contradiction between achieving metallic appearance and providing resistance to mechanical influences.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses thin film coating technology to apply multiple layers, each with specific mechanical properties. The thin film structure allows for optimized mechanical performance while maintaining the desired metallic appearance, addressing the susceptibility to mechanical damage.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If electroplating is used to provide metallic appearance, then the metallic appearance and durability are improved, but environmental strain increases significantly

Engineering Contradiction:

Improvedurability and metallic appearanceVSAvoidenvironmental strain

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the electrochemical electroplating process with a physical vapor deposition (PVD) process. This substitution eliminates the environmental concerns associated with electroplating chemicals and waste while maintaining the durability and metallic appearance through physical deposition of metal layers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The PVD process is conducted in a vacuum or controlled inert atmosphere, eliminating the need for chemical baths and reducing environmental impact. This inert environment approach provides a cleaner, more environmentally friendly alternative to traditional electroplating.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Shape

If a PVD layer is used as the outermost layer, then the metallic appearance is achieved, but the coating is not suitable for exterior use exposed to stone chipping and weather conditions

Engineering Contradiction:

Improvemetallic appearanceVSAvoidresistance to stone chipping and weather conditions

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite coating system where a PVD metallic layer is combined with a polymeric topcoat layer. This composite structure provides both the metallic appearance from the PVD layer and the weather resistance and stone chip resistance from the polymeric topcoat, making the component suitable for exterior automotive use.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies a protective topcoat layer beforehand to cushion and protect the underlying PVD metallic layer from mechanical damage such as stone chipping and environmental degradation. This prior protective measure ensures the durability required for exterior components.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 method effectively achieves a durable, adjustable gloss level on plastic substrates, enhancing their resistance to mechanical influences and weather conditions while maintaining a metallic appearance, suitable for exterior automotive components.

Implementation Method 1

a UV-hardened paint coat is applied to the metallic surface; the polymers of the mixed paint are cross-linked by means of UV radiation

Methodology Applied

Scientific EffectUV hardening: Photopolymerisation

Data Source

PatentUS10273576B2Gloss degree adjustment of plastics substrates having a metallic finish

Publication Date: 2019.04.30 OERLIKON SURFACE SOLUTIONS AG PFAFFIKON

AI summary

A method for producing a component with a predetermined gloss level, including the steps of: preparing a component with a metallic surface; producing a matte/glossy mixture by mixing glossy paint and matte paint in a predetermined mixing ratio; applying the matte/glossy mixture to the metallic surface of the component; and cross-linking the matte/glossy mixture.