Vehicle Trim Part Surface Quality via Direct Lacquer Coating
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Solution Overview
Problem
The production of vehicle trim parts with intermediate layers like wood veneer is time-consuming and costly, and direct lacquer application on fiber-reinforced plastic supports results in visual defects due to fiber penetration, which are not acceptable for a 'Class A' surface.
Innovation Solution
A method involving the direct coating of a lacquer layer on a fiber composite support substrate, followed by a protective layer to conceal inhomogeneities, eliminating the need for intermediate processing steps and ensuring a visually flawless surface by forming a homogeneous protective layer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an intermediate layer (wood veneer) is used between the fiber-reinforced plastic support and the lacquer layer, then the surface quality is improved and visual defects are prevented, but the production time and cost increase due to additional machining and joining steps
Solution Approach 1:
The patent removes the intermediate layer (wood veneer) from the structure, allowing direct application of lacquer to the fiber-reinforced plastic support. This extraction of the intermediate component eliminates the associated machining and joining steps while maintaining surface quality through direct lacquer coating.
Solution Approach 2:
The patent merges the support substrate and lacquer layer into a direct bond, eliminating the intermediate layer. This consolidation reduces the number of components and processing steps (no separate machining and joining operations), thereby reducing production time and cost while achieving the desired surface quality.
2Productivity
If the lacquer layer is applied directly on the fiber-reinforced plastic support without an intermediate layer, then production time and cost are reduced, but visual defects occur due to fiber penetration through the lacquer layer
Solution Approach 1:
The patent modifies the parameters of the lacquer layer, specifically increasing its thickness to 0.5-2 mm and adjusting its composition (using effect lacquers with pigments, metallic particles, or pearlescent particles). These parameter changes enable the lacquer layer to adequately cover the fiber reinforcement while maintaining a visually flawless surface.
Solution Approach 2:
The patent employs a composite lacquer layer containing multiple components (binders, pigments, metallic particles, or pearlescent particles) that work together to provide both structural integrity and visual perfection. This composite formulation allows the lacquer to mask fiber penetration while maintaining the desired aesthetic appearance.
3Reliability
If multiple mechanical and chemical processing stages are applied to prepare the intermediate layer for lacquer application, then the lacquer adhesion is improved, but the surface structure is substantially removed and visual defects are created
Solution Approach 1:
The patent removes the intermediate layer that would require mechanical and chemical processing. By eliminating this intermediate component, the need for cutting, sanding, and staining operations is removed, preventing surface structure degradation while maintaining adequate lacquer adhesion through direct bonding to the support.
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 significantly reduces production time and cost while achieving a visually flawless surface, with inhomogeneities from fiber protrusions being concealed by the protective layer, making the trim part more economical and aesthetically appealing.
Implementation Method 1
A support substrate is produced from a fiber composite material comprising fibers by injecting the fiber composite material into a mold cavity of an injection mold
Implementation Method 2
A lacquer layer is formed by directly coating the surface of the support substrate with a lacquer
Implementation Method 3
The lacquer layer is coated with a protective layer. The protective layer forms a homogeneous protective layer surface that defines the visible side
Data Source
AI summary
A method for producing a trim part (1) with a visible side (S) for use in vehicles has steps of producing a support substrate (2) from a fiber composite material. The fiber composite material is injected into a mold cavity of an injection mold. A surface is formed on a first side of the support substrate (2) that faces the visible side (S) of the trim part (1). A lacquer layer (3) is formed by directly coating the surface of the support substrate (2). The lacquer layer (3) is coated with a protective layer (4).