Patent Publication Number: US-2023136173-A1

Title: Laser marking system for vehicle body customization

Description:
INTRODUCTION 
     The subject disclosure relates to the art of vehicles and, more particularly, to a laser marking system for customizing a vehicle body. 
     When purchasing a new vehicle, consumers are faced with a wide range of available options. One such option is choosing an exterior color for the vehicle. Other options may include trim packages which include decals that are attached to exterior surfaces of the vehicle. Often times, a consumer will purchase a vehicle having a particular exterior color with an intention to add further embellishment. 
     Additional embellishments may include colorful wraps that impart design elements to the exterior color, add personalized symbols, and/or otherwise allow the consumer to personalize the vehicle. In other cases, the consumer will add painted features to the exterior color in an effort to personalize the vehicle. In either instance, the additional embellishments are applied over a clear coat and often times do not adhere as desired. Further, incorporating the additional embellishments into the vehicle is time consuming and costly. Often times, when adding design elements, the consumer will lose access to the vehicle for a week or more. An ability to personalize the vehicle at a point of purchase would reduce costs, allow the embellishments to be better integrated into the vehicle finish, and eliminate loss of access to the vehicle as the embellishments will be completed at the time of delivery. 
     SUMMARY 
     Disclosed, in accordance with a non-limiting example, is a method of customizing a vehicle body including inputting a selected customized embellishment to a laser controller, directing a beam of the laser onto a surface of the vehicle body, and guiding the beam of the laser with the laser controller to impart the selected customized embellishment to the surface. 
     In addition to one or more of the features described herein directing the beam of the laser onto the surface of the vehicle body includes directing the beam of the laser onto an unpainted surface to create the selected customized embellishment. 
     In addition to one or more of the features described herein forming a pattern replicating tool marks on the unpainted surface with the laser. 
     In addition to one or more of the features described herein controlling one of an intensity of the beam of the laser and incident angles of the beam of the laser to generate a color change in the unpainted surface. 
     In addition to one or more of the features described herein removing portions of at least one layer of paint from a painted surface of the vehicle body with the beam of the laser and revealing a second layer of paint below the at least one layer. 
     In addition to one or more of the features described herein removing the portions of the at least one layer with the beam of the laser includes removing a portion of a first layer having a first color and removing a portion of a second layer having a second color. 
     In addition to one or more of the features described herein removing the portion of the second layer with the beam of the laser reveals a third color. 
     In addition to one or more of the features described herein removing another portion of the first layer with the beam of the laser to expose the second color. 
     In addition to one or more of the features described herein removing the portion of the first layer with the beam of the laser includes controlling the beam of the laser to penetrate the painted surface a first depth. 
     In addition to one or more of the features described herein removing the portion of the second layer with the beam of the laser includes controlling the beam of the laser to penetrate the painted surface a second depth. 
     In addition to one or more of the features described herein controlling the beam of the laser to penetrate the painted surface a second depth includes penetrating the second layer a depth that is distinct from the first depth. 
     In addition to one or more of the features described herein a vehicle includes the vehicle body formed by the method described herein. 
     Also disclosed, in accordance with a non-limiting example, a method of customizing a painted surface having at least two layers of paint each having a different color includes inputting a selected customized embellishment to a laser controller, removing a portion of a first layer of the at least two layers with a beam of a laser to reveal a portion of a second layer of the at least two layers to impart the selected customized embellishment on the painted surface. 
     In addition to one or more of the features described herein removing another portion of the first layer with the beam of the laser to expose another portion of the second layer. 
     In addition to one or more of the features described herein removing a portion of a third layer of the at least two layers with the beam of the laser to reveal a portion of a fourth layer of the at least two layers. 
     In addition to one or more of the features described herein removing the portion of the first layer includes controlling the beam of the laser to penetrate the painted surface a first depth. 
     In addition to one or more of the features described herein removing the portion of the second layer with the beam of the laser includes controlling the beam of the laser to penetrate the painted surface a second depth. 
     In addition to one or more of the features described herein controlling the beam of the laser to penetrate the painted surface a second depth includes penetrating the second layer a depth that is distinct from the first depth. 
     In addition to one or more of the features described herein controlling the beam of the laser to impart multiple embellishments in the painted surface. 
     In addition to one or more of the features described herein a vehicle having a painted surface is formed by the method described herein. 
     The above features and advantages, and other features and advantages of the disclosure are readily apparent from the following detailed description when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other features, advantages and details appear, by way of example only, in the following detailed description, the detailed description referring to the drawings in which: 
         FIG.  1    depicts a vehicle including a body having a customized surface formed in accordance with a non-limiting example; 
         FIG.  2    depicts a laser system for creating a customized surface in accordance with a non-limiting example; 
         FIG.  3    depicts a multi-layered painted surface being customized by the laser system of  FIG.  2   , in accordance with a non-limiting example; 
         FIG.  4    depicts the vehicle body of  FIG.  1    with an open door showing an inner surface having an embellishment created, in accordance with a non-limiting example; and 
         FIG.  5    is a detailed view of the embellishment of  FIG.  4   , in accordance with a non-limiting example. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. As used herein, the term module refers to processing circuitry that may include an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality. 
     A vehicle, in accordance with a non-limiting example, is indicated generally at  10  in  FIG.  1   . Vehicle  10  includes a body  14  supported on a frame (not shown) and a plurality of wheels, one of which is indicated at  19 . Body  12  includes a surface  22  that has applied thereto a number of painted layers  24 . In a non-limiting example, a customized embellishment  28  is created on surface  22 . In a non-limiting example, customized embellishment  28  is created by removing portions of one or more of painted layers  24  applied to surface  22 . 
     Referring to  FIG.  2   , a laser system  33  is shown to include a laser  35  connected to a laser controller  37 . Laser controller  37  directs a beam  70  from laser  35  to create customized embellishment  28  on surface  22 . In a non-limiting example, laser controller  37  includes a central processing unit (CPU)  39  operatively and functionally connected to a non-volatile memory  41 , and a laser control module  43 . In a non-limiting example, laser control module  43  controls the power of beam  70  emitted from laser  35  to have desired penetration depth as well as guiding laser system  33  in terms of an moving path of emitted beam  70 , defocus distance and incident angles to surface  22  to remove select portions of painted layers  24  to create customized embellishment  28 . 
     Referring to  FIG.  3   , in a non-limiting example, painted layers  24  includes a first layer  46  having a first thickness, a second layer  48  having a second thickness, a third layer  50  having a third thickness, a fourth layer  60  having a fourth thickness, and a fifth layer  62  having a fifth thickness that is applied to an unpainted surface  63  of body  12 . Fifth layer  62  may take the form of a paint primer and first layer  46  may take the form of a clear coat. Second layer  48 , third layer  50 , and fourth layer  60  may take the form of various layers of different colored paint. It should be understood that the number, type, and color of each layer may vary. It should also be understood that each of the first thickness, second thickness, third thickness, fourth thickness, and fifth thickness may be similar or different depending upon paint type, paint color, coverage, and the like. 
     In a non-limiting example, laser controller  37  may control laser  35  based on instructions stored in laser control module  43  and a pattern that may be stored on non-volatile memory  41 . Beam  70  from laser  35  may be guided to remove one or more portions of the first layer  46 , second layer  48 , third layer  50 , and a fourth layer  60  in order to create a selected design that forms customized embellishment  28 . The design may be selected prior to production and created toward an end of a production process, or after purchase. The design may be chosen from a number of available designs or could be unique to, and supplied by, a consumer via an input  65  fed into laser controller  37 . 
     In another non-limiting example depicted in  FIGS.  4  and  5   , a customized embellishment  80  may be applied to unpainted surface  63  in selected areas of vehicle  10 . In a non-limiting example, customized embellishment  80  may take the form of simulated tool marks  84  as shown in  FIG.  5   , such as would be made by an angle grinder. It should be understood that various other designs, simulated tool marks, and the like may be integrated into one or more surfaces of vehicle  10  through operation of laser system  33 . Embellishments may be added during and/or after production. Embellishments may be factory added or created at a dealership. 
     While the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from its scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within the scope thereof.