Vehicle Wheel Coating Ablation for Two-Tone Patterns Without Heat Damage
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Solution Overview
Problem
Vehicle wheel manufacturers face challenges in achieving a multi-color or two-tone appearance through mass production due to issues with paint masks causing defects and heat damage from laser ablation, which limits the process to only exposing the alloy substrate, resulting in insufficient contrast between ablated and non-ablated areas.
Innovation Solution
A method involving the application of a first polymeric coating with a second polymeric coating of a different color, followed by a clear intermediate coating, where the laser ablates the second coating to expose the first coating, creating a unique two-tone appearance without damaging the underlying coating by using a clear polymer coating with a greater film thickness to mitigate heat damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a paint mask is applied over an existing coating prior to application of a second coating, then a multi-color appearance can be achieved, but paint defects such as paint sags and paint contamination occur
Solution Approach 1:
The patent segments the coating process into multiple layers (first polymeric coating, intermediate clear polymeric coating, second polymeric coating) that are applied sequentially. The laser ablation process further segments the visible appearance by selectively removing portions of the second coating to reveal underlying layers, creating the multi-color effect without requiring physical masks.
Solution Approach 2:
The intermediate clear polymeric coating serves as a mediator layer between the first colored coating and the second colored coating. This intermediate layer protects the first coating during the application and curing of the second coating, and its selective removal by laser ablation reveals the first coating's color, enabling the multi-color appearance without direct contact between mask and paint layers.
2Shape
If laser ablation is used to remove color coatings, then a two-tone appearance can be achieved, but heat damage occurs to adjacent areas of the coating
Solution Approach 1:
The intermediate clear polymeric coating acts as a thermal buffer or intermediary layer between the laser energy and the first colored polymeric coating. This clear coating has sufficient thickness to absorb and dissipate the heat generated during laser ablation of the second coating, preventing thermal damage to the underlying first coating while still allowing the laser to effectively remove the second coating in the desired pattern.
Solution Approach 2:
The patent changes the physical parameters of the coating system by introducing an intermediate layer with specific optical and thermal properties. This intermediate layer's thickness and material composition are optimized to allow laser penetration and ablation of the second coating while maintaining thermal protection for the first coating, effectively changing the thermal conductivity and heat capacity parameters of the coating system.
3Shape
If laser ablation is used to etch the alloy substrate, then contrast between ablated and non-ablated areas is improved, but the process is limited to exposing only the substrate without preserving underlying coatings
Solution Approach 1:
The patent segments the coating structure into multiple removable layers (second polymeric coating and intermediate clear polymeric coating) that can be selectively removed by laser ablation. This segmentation allows the process to achieve high contrast by removing only the top layers while preserving the first polymeric coating underneath, providing versatility in designing different multi-color patterns and appearances.
Solution Approach 2:
The patent adds a vertical dimension to the color appearance by creating a layered structure where different colors are positioned at different depths. The laser ablation process selectively removes material in the vertical direction to reveal underlying colors, transforming a single-layer color application into a multi-dimensional color display with enhanced contrast and design flexibility.
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 allows for a unique two-tone appearance with programmable patterns, reducing the risk of defects and maintaining the durability of the vehicle wheel by selectively removing the second polymeric coating and a portion of the intermediate coating, while preventing damage to the first polymeric coating.
Implementation Method 1
A laser scans a pattern over the second polymeric coating resulting in ablation of the second polymeric coating rendering the first polymeric coating visible through the intermediate clear polymeric coating
Data Source
AI summary
A vehicle wheel and method of manufacturing the vehicle wheel is disclosed. A first polymeric coating is applied to a surface of an alloy substrate that defines the vehicle wheel. The first polymeric coating defines a first coloration. An intermediate clear polymeric coating is applied over the first polymeric coating. A second polymeric coating is applied over the first polymeric coating with the second polymeric coating defining a second coloration that is distinguishable from the first coloration. A laser scans a pattern over the second polymeric coating resulting in ablation of the second polymeric coating rendering the first polymeric coating visible through the intermediate clear polymeric coating defining a pattern of exposed first polymeric coating. Thus, a two-tone appears is present between the first coloration and the second coloration in the shape of the pattern scanned by the laser.