Automated Vehicle Body Painting Pattern Application

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Solution Overview

Problem

The existing painting methods for motor vehicle body parts require multiple layers of paint and manual application of decorative patterns, leading to additional clear coat layers, increased costs, and errors due to the need for masking materials and complex processes.

Innovation Solution

Applying the pattern directly to the base coat layer without an intermediate clear coat layer, allowing for a single clear coat layer that covers both the base coat and pattern, and using a multi-axis painting robot for automated application in a wet-on-wet or 3-wet process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a clear coat layer is applied before the pattern, then the pattern is protected during application, but an additional clear coat layer and drying step are required

Engineering Contradiction:

Improvepattern application qualityVSAvoiddrying time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent removes the intermediate clear coat layer from the painting process. The pattern is applied directly to the base coat layer without requiring a clear coat barrier, thereby eliminating the associated drying time while maintaining pattern application quality through direct adhesion to the base coat.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the pattern application step with the base coat layer, eliminating the separate clear coat layer. This merging of layers reduces the total number of drying steps required while ensuring the pattern adheres directly to the base coat, maintaining reliability without the time penalty.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If manual application of the pattern is used, then flexibility in pattern design is achieved, but covering material and disposal costs increase

Engineering Contradiction:

Improvepattern design flexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical application with an automated spray system. The application device deposits pattern material directly onto the base coat layer through spraying, eliminating the need for manual handling of covering materials while maintaining design flexibility through programmable deposition patterns.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the application method from manual to automated spraying, altering the physical parameters of material deposition. This enables precise control over pattern application without requiring covering materials, reducing manufacturing costs while preserving design adaptability through digital control of the spray system.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If manual application of the pattern is used, then human judgment in pattern placement is possible, but the number of errors increases

Engineering Contradiction:

Improvepattern placement controlVSAvoidpattern application accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces manual application with an automated spray system that provides precise control over pattern placement. The automated system eliminates human error in pattern positioning while maintaining operational ease through programmable deposition control, thereby improving manufacturing precision without sacrificing ease of operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements automated control with feedback mechanisms that monitor and adjust pattern deposition in real-time. This ensures accurate pattern placement by continuously comparing actual deposition with target specifications, eliminating errors associated with manual judgment while maintaining ease of operation through automated correction.

Inventive Principle:

Principle #23Feedback

4Reliability

If multiple clear coat layers are applied, then complete coverage and protection are achieved, but the painting process becomes more complex

Engineering Contradiction:

Improvepaint coverage qualityVSAvoidpainting process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the intermediate clear coat layer from the multi-layer painting process. By applying the pattern directly to the base coat, the system eliminates one layer and its associated application and drying steps, reducing process complexity while maintaining complete coverage and protection through the remaining clear coat layer applied over the pattern.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the pattern application with the base coat layer, eliminating the need for a separate clear coat barrier. This consolidation reduces the number of painting steps and overall process complexity while ensuring adequate coverage and protection is achieved through the single clear coat layer applied over the completed pattern.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2953733B1Painting method

Publication Date: 2020.04.01 DUERR SYST AG

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AI summary

A method for painting a component such as a motor vehicle body component includes applying to the component a base coat layer, a pattern such as a decorative strip or a graphic element, and applying a clear lacquer coat. The pattern (7) is applied to the base coat layer without interposing a clear lacquer coat. A corresponding painting facility is provided.