Description:SCRATCH RESISTANT STYLING PANEL OF A VEHICLE
TECHNICAL FIELD
[0001]
The present subject matter generally relates to a styling panel of a vehicle. More particularly, but not exclusively to a styling panel of the vehicle that is scratch-resistant and can be used in vehicle bodywork.
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BACKGROUND
[0002]
The existing vehicles face an intricate problem of protecting their bodyworks such as, but not limiting to, fenders, side panels or mudguard panels after being rubbed against any hard surface or on receiving a heavy load. On receiving a heavy load, such panels may face severe scratches and 10 abrasions, which is highly undesirable for appeal of the vehicle as well as life and performance of the vehicle. Thus, there exists a need to protect the panels from scratches and abrasions.
[0003]
Mostly, organic polymer material is used to fabricate the panels which are then used as per the requirement in the bodyworks of the vehicle. These 15 panels require additional processing to ensure protection against the unwanted and undesired scratches or abrasions. These scratches and abrasions are a result of loading conditions which the panel faces when being accommodated as a bodywork of vehicle.
[0004]
In the conventional state-of-the-art, the method for producing a 20 scratch resistance composition consists of a thermoplastic organic polymer. This polymer is then reactively mixed with a first material to make a mixture which can resist the scratches and abrasions. Furthermore, the first material may contain silicon based anti-scratch additive master batch. This, as the conventional art states is done after the part is fabricated as a spraying coating 25 or a layer which is applied after the part is produce. However, it should be noted that these methods may create unnecessary complex manufacturing process which can involve a plurality of steps. Thus, resulting in limited applicability and compatibility issues between the additive masterbatch and
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the organic polymer.
Moreover. this also leads to increased cost of such parts with unknown long-term durability.
[0005]
Hence, there exists a need to fabricate a scratch resistant vehicle styling panel that needs no further scratch resistant layer application to ward off scratches formed on rubbing against any hard surface or on collision with 5 another surface.
[0006]
Thus, there is a need in the art for a vehicle and a method of producing scratch-resistant part, that can be used in the bodyworks of a vehicle which addresses at least the aforementioned problems and other problems of known art. 10
[0007]
Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described methods with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings. 15
[0008]
Moreover, there exists a need to develop a vehicle and a method to produce scratch-resistant part during the manufacturing process itself so that the parts when fabricated does not need to be processed at another stage.
SUMMARY OF THE INVENTION 20
[0009]
According to embodiments illustrated herein, the present invention is a vehicle with a scratch resistant styling panel. The scratch resistant styling panel is fabricated from a mixture comprising pellets of a thermoplastic polymer and pellets of a scratch resistant additive. The scratch resistant additive is silicone masterbatch and the thermoplastic polymer is 25 polypropylene. The panel is fabricated using injection moulding. The scratch resistant additive has a density lower that the density of the thermoplastic polymer. The master batch of Si-based anti-scratch additive is added while the polypropylene pellets are being injection moulded. Over the portions that will resist the undesirable scratch, that additive will create a protective 30 coating post injection moulding and part formation. Anti scratch additive will make one protective layer on the top surface of the parts. And that additives
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are very much mechanically stiff, and it will absorb the load coming due to
scratch and will not allow to transfer the load on the base polypropylene polymer. As, base polymer is not getting any load, it will be scratch free part and good aesthetic view of the vehicle will be maintained.
[00010]
The composition of the anti-scratch additive chemical 5 additives that need to be added in polymer material matrix is optimised to get the maximum scratch resistance property of the parts without disturbing the base polymer structure. This process requires the selection of right volume of chemical agent that can easily couple with the polypropylene material because the melting point of both material is different. The base material is 10 so selected to achieve uniform dispersion of these chemical agent in the component in a uniform manner.
[00011]
A silicon based anti-scratch additive is mixed with the organic polymer should be in such an optimized dosage, which makes a matrix structure over the fabricated part ensuring protection against scratches and 15 abrasions. Moreover, this method must be included in the manufacturing process itself, such as but not limited to the process of injection moulding or injection-formed manufacturing where the fabricated part comprises the characteristics of anti-scratch properties and does not need to be processed again at a later stage. 20
[00012]
The method and the vehicle as described in the present disclosure elaborates on a way to protect the polymer parts which are prone to cracks in the presence of small scratch. This results in increased lifetime of the vehicle and the vehicle body parts. It also enhances the impact property as the additive when mixed in an optimized dosage percentage as the 25 masterbatch with the polymer granules ensures the top layer and the surface of the parts be protected against unwanted scratches and abrasions while also making sure the part and the vehicle has good stiffness.
[00013]
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and 30 are not restrictive of the invention, as claimed.
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BRIEF DESCRIPTION OF DRAWINGS
[00014]
The detailed description is described with reference to the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[00015]
Fig. 1 exemplarily illustrates a schematic diagram of the injection 5 moulding process to obtain a scratch resistant styling panel.
DETAILED DESCRIPTION OF INVENTION
[00016]
A vehicle comprises a plurality of panels that serve a purpose as well as contribute to the aesthetic appeal of the vehicle. Such panels are the 10 exterior panels, interior panels, trim components, mud guard, body cover of the vehicle, etc. The vehicle can be a two-wheeled vehicle, a three wheeled vehicle, a four wheeled vehicle or any multi wheeled vehicle, irrespective of the power train of the vehicle. The scratch resistant styling panel of the present invention can be any panel or all panels of the vehicle. In an 15 embodiment, the scratch-resistant styling panel is selected from the group consisting of body panels, bumpers, trim components, and interior components of the vehicle. In embodiment, the scratch resistant styling panel is integrated into at least one of a vehicle exteriors surface and a vehicle interior surface, enhancing the overall durability and visual appeal of the 20 vehicle.
[00017]
Fig. 1 exemplarily illustrates a schematic diagram of the injection moulding 103 to obtain a scratch resistant styling panel 104. The scratch resistant styling panel is fabricated from a mixture comprising a plurality of pellets of a thermoplastic polymer and a plurality of pellets of a scratch-25 resistant additive. The scratch resistant styling panel 104 being fabricated using injection moulding of the mixture. The scratch resistant additive 102 has a lower density compared to density of the thermoplastic polymer. The scratch resistant additive 102 is silicone based masterbatch and the thermoplastic polymer 101 is polypropylene. The master batch of Si-based 30 anti-scratch additive 102 is added while the polypropylene pellets 101 are
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being injection moulded. Over the portions that will resist the undesirable
scratch, the additive will create a protective coating post injection moulding and part formation.
[00018]
A masterbatch is typically a solid additive for plastic or other polymer which is used to impart desired properties to this plastic or other 5 polymer. A masterbatch is typically a concentrated mixture of additives encapsulated into a carrier resin during a process involving heat, which is then cooled and cut into granular shape. This enables to impart desired properties to a polymer. Masterbatches are typically in solid form at ambient temperature, usually in pelletized format. Siloxane masterbatches are 10 typically pelletized micro-dispersions of siloxane polymers, in various different plastic carrier resins at different loadings. Siloxane is a compound which contains at least one Si—O—Si link. A polymer is a compound containing repeating units. A plastic or organic thermoplastic material or thermoplastic organic polymer is a polymer based on C—C links and having 15 thermoplastic properties. A siloxane polymer also called polysiloxane or silicone is a polymer containing repeating Si—O—Si units. An organopolysiloxane compound is a polysiloxane bearing substituents which constituents contain organic moieties.
[00019]
Pellets of Siloxane 102 and thermoplastic polymer 101 will be fed 20 into the injection moulding process 103. So that when the mixture is done at higher temperature and the treated during moulding section. The hard material part will stay above the polymer as a matrix structure such that the melded part itself will act as scratch free additive. The mixture comprises 0.5% to 10% by weight of the additive 102. In an embodiment, the scratch-25 resistant additive 102 is the silicone based masterbatch in a range of 2% to 5% by weight. In an embodiment, the scratch resistant additive is 3% by weight of Si based master batch granules 102.
[00020]
The injection moulding 103 of the mixture being performed at temperatures ranging from 180°C to 240°C for the thermoplastic polymer and 30 a mold temperature ranging from 20°C to 80°C. Injection pressures ranging
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from 5000 psi to 20000 psi, with a pre
-defined cycle time to ensure proper filling, packing, cooling, and ejection of the styling panel 104.
[00021]
The scratch-resistant additive forms a protective top layer of matrix structure on the scratch resistant styling panel 104, for load-bearing capacity of the scratch resistant styling panel 104 and protection of the scratch resistant 5 styling panel 104 against scratches and abrasions. Initially, the polymer pellets 102 that are acquired used in any normal part production. The polymer pellets 102 are liquified and after the liquification pushed through an injection moulding setup, which then takes the form of the panel. First the pellets 102 and the additives are mixed and then melted. Silicon based anti-scratch 10 additive master batch 103 is added and mixed together. The equipment for melting and blending is for example, a twin screw extruder, a Banbury mixer, a two-roll mill or a single-screw extruder, either with or without a mixing head.
[00022]
While melting, due to the density difference between the 15 polypropylene and anti-scratch additive material, the anti- scratch additive materials are disposed on the top surface because of its lesser density. Thus, the silicon based anti-scratch additive forms a matrix state of structure which will prevent any hard rub and damage against the material surface of the part.
[00023]
In an embodiment, the scratch resistant styling panel 104 undergoes 20 a surface treatment process to further enhance its scratch resistance, aesthetic appeal, corrosion resistance, and longevity. In embodiment, in addition to the scratch resistant additives, other additives such as fillers, for example talc, calcium carbonate, kaolin or wollastonite may be added to the thermoplastic polymer. The additives may comprise pigments, for example carbon black or 25 titanium dioxide. The additives may comprise additives such as antioxidants and/or UV stabilisers. Such additives can be mixed with the thermoplastic organic polymer (P) either before or after it is mixed with the masterbatch, or can be incorporated in the masterbatch.
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[00024]
In another embodiment, wherein the scratch resistant styling panel 104 further comprises a surface texture or pattern imparted during the injection moulding process to enhance aesthetics and tactile feel.
[00025]
In an embodiment, the scratch resistant styling panel 104 is translucent or transparent, allowing for integration of lighting elements or 5 displays within the panel for enhanced functionality and aesthetic appeal. In another embodiment, the scratch resistant styling panel 104 includes embedded sensors or electronic components for vehicle monitoring, communication, or control purposes.
[00026]
The scratch resistant styling panel 104 is configured to withstand 10 environmental stressors, including ultraviolet exposure, temperature fluctuations, and chemical exposure, without compromising its scratch resistance or structural integrity. In an embodiment, the scratch resistant styling panel 104 is recyclable, contributing to environmental sustainability and reducing the vehicle's carbon footprint. 15
[00027]
The scratch resistant styling panel of the present invention possesses scratch resistance, abrasion resistance, higher load bearing capacity, offers good aesthetic appeal to the vehicle, no visible dents on the body of vehicle offering long service time, and high impact strength.
[00028]
Anti scratch additive will make one protective layer on the top 20 surface of the parts. The additives are very much mechanically stiff, and will absorb the load coming due to scratch and will not allow to transfer the load on the base polypropylene polymer. As the base polymer does not get any load, it will be scratch free part and good aesthetic view of the vehicle will be maintained. Further, service downtime of the vehicle to correct the dents is 25 reduced and performance of the vehicle is improved. Manufacturability and assembly of the such styling panels and the vehicle having such panels is improved. From economic standpoint, the cost of production of such panels is reduced since no additional surface treatment is done to achieve the styling panel, but instead in the injection moulding phase itself, the scratch resistant 30 styling panel is produced. Handling of the vehicle is improved since it is
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abrasion resistant and mud resistant
. The scratch resistant styling panel 104 exhibits improved resistance to scratches, abrasions, and wear compared to conventional vehicle styling panels.
[00029]
Improvements and modifications may be incorporated herein without deviating from the scope of the invention. , Claims:We Claim:
1.
A vehicle comprising a scratch resistant styling panel (104), the vehicle comprising:
said scratch resistant styling panel (104) fabricated from a 5 mixture comprising a plurality of pellets of a thermoplastic polymer and a plurality of pellets of a scratch-resistant additive,
wherein said scratch resistant additive having a lower density compared to density of the thermoplastic polymer, and
wherein said scratch resistant styling panel (104) being 10 fabricated using injection molding of said mixture.
2.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein the scratch resistant additive being silicone based masterbatch and wherein the thermoplastic polymer being poly propylene. 15
3.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein said mixture comprising 0.5% to 10% by weight of said additive and wherein injection molding of said mixture being performed at temperatures ranging from 180°C to 240°C for the thermoplastic polymer and a mold temperature ranging from 20°C to 20 80°C, and at injection pressures ranging from 5000 psi to 20000 psi, with a pre-defined cycle time to ensure proper filling, packing, cooling, and ejection of the panel.
4.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein the scratch-resistant additive forms a 25 protective top layer of matrix structure on the scratch resistant styling panel 104, for load-bearing capacity of the scratch resistant styling panel (104) and protection of the scratch resistant styling panel (104) against scratches and abrasions.
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5.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein the scratch-resistant additive comprises the silicone masterbatch scratch-resistant additive in a range of 2% to 5% by weight.
6.
The vehicle comprising a scratch resistant styling panel (104) as 5 claimed in claim 1, wherein the scratch resistant styling panel (104) is selected from the group consisting of body panels, bumpers, trim components, and interior components of the vehicle.
7.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein said scratch resistant styling panel (104) 10 being integrated into at least one of a vehicle exteriors surface and a vehicle interior surface, enhancing the overall durability and visual appeal of the vehicle.
8.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein the scratch resistant styling panel (104) 15 undergoes a surface treatment process to further enhance its scratch resistance, aesthetic appeal, corrosion resistance, and longevity.
9.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein the scratch resistant styling panel (104) further comprises a surface texture or pattern imparted during the 20 injection molding process to enhance aesthetics and tactile feel.
10.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein the scratch resistant styling panel (104) is one of translucent and transparent, allowing for integration of lighting elements or displays within the panel for enhanced functionality and 25 aesthetic appeal.
11.
The vehicle comprising a scratch resistant styling panel (104) as claimed in claim 1, wherein the scratch resistant styling panel (104) includes embedded sensors or electronic components for vehicle monitoring, communication, or control purposes. 30
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12.
The vehicle comprising a scratch resistant styling panel (104) asclaimed in claim 1, wherein the scratch resistant styling panel (104) isconfigured to withstand environmental stressors, including ultravioletexposure, temperature fluctuations, and chemical exposure, withoutcompromising its scratch resistance or structural integrity.5
13.
The vehicle comprising a scratch resistant styling panel (104) asclaimed in claim 1, wherein the scratch resistant styling panel (104) isrecyclable, contributing to environmental sustainability and reducingthe vehicle's carbon footprint.