Backlit Decorative Surface Perforation Adhesive Intrusion
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Solution Overview
Problem
The challenge in creating backlit decorative surfaces using non-transparent or translucent materials like leather or artificial leather for vehicle interiors is that introducing holes or perforations for light passage leads to unsightly adhesive intrusion and uneven light distribution, which is difficult to manage in industrial serial production.
Innovation Solution
A latently reactive adhesive film is applied to the rear side of the decorative material, allowing perforations to be introduced without adhesive intrusion, and then activated under temperature and pressure to form a permanent bond with the illumination device, ensuring uniform and aesthetically pleasing transillumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If holes or perforations are introduced into the decorative material to allow light passage, then light transmission is improved, but adhesive material intrudes into the holes causing unsightly appearance and uneven light distribution
Solution Approach 1:
The adhesive film is applied to the rear side of the decorative material before the perforations are introduced. This preliminary action prevents adhesive from intruding into the holes during the bonding process, eliminating the unsightly appearance and ensuring uniform light distribution through the perforations.
2Strength
If adhesive material is applied onto the rear side of the decorative material to bond it to the diffuser or light guide, then bonding is achieved, but adhesive intrudes into the perforations causing visible defects and non-uniform illumination
Solution Approach 1:
A separate adhesive film is introduced as an intermediary layer between the decorative material and the bonding process. This film is applied to the rear side of the decorative material before perforation, acting as a barrier that prevents adhesive intrusion into the holes while still enabling effective bonding to the diffuser or light guide.
3Productivity
If decorative material is stored for multiple weeks before lamination, then production flexibility is improved, but maintaining material integrity and perforation quality becomes difficult
Solution Approach 1:
The adhesive film is applied and the decorative material is prepared in advance before final lamination. This preliminary preparation allows the material to be stored for multiple weeks with the adhesive film already in place, maintaining its integrity and preventing degradation, while enabling flexible production scheduling.
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 visually appealing and reproducible backlighting while meeting industrial production requirements, enabling storage and later activation for bonding, ensuring consistent light distribution and maintaining material integrity.
Implementation Method 1
a film adheres to the rear side of the decorative material, which, under the effect of a pressure p2, and/or under a temperature increase to a temperature T2, can be permanently adhesively-bonded or laminated onto the illumination device
Data Source
AI summary
A planar decorative material (11), for interior furnishing, with perforations (12), in particular for the automotive industry, which serves to be illuminated, on its rear side (13), with a illumination device (18) and permits a part of the light of the illumination device (18) to pass from the rear side (13) of the decorative material (11) through the perforations (12) to the visible side (14) of the decorative material (11), wherein a film (20) adheres onto the rear side (13) of the decorative material (11), and the perforations (12) extend through the film (20) as far as to the visible side (14) of the decorative material (11), and the film (20) is an adhesive film activatable by increase in temperature and/or pressure, which can be permanently adhesively-bonded onto the illumination device (18) under increase in temperature to a temperature T2 and/or increase in pressure to a pressure p2. The present invention also relates to a manufacturing method.