Perforated Backlit Vehicle Panel With Leather-Covered Pixel Display
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Solution Overview
Problem
The automotive industry faces challenges in adhering leather to molded vehicle interior parts effectively, resulting in loose leather, diminished natural grain appearance, and high labor costs, especially when trying to achieve a smooth finished leather look with raised seams.
Innovation Solution
A low-profile, backlit panel assembly with a substrate panel perforated by a two-dimensional array of closely-spaced holes for semiconductor-based lighting devices, where the light emitted through these holes creates a pixelated image, and a continuous membrane, including leather, provides a background for the image, allowing for controlled luminous intensity and color.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leather is glued or adhered over molded vehicle interior parts, then the leather can cover the substrate, but the leather will loosen and peel away from the underlying substrate over time
Solution Approach 1:
The patent introduces a specialized adhesive system as an intermediary between the leather and the molded substrate. This adhesive layer serves as a mediator that creates strong bonding between the two materials, preventing the leather from loosening and peeling away over time while maintaining the aesthetic appearance of the finished product.
2Reliability
If multiple leather pieces are sewn or made from to cover molded parts, then the coverage can be achieved, but raised seams are created and labor costs increase
Solution Approach 1:
The patent divides the leather coverage into multiple sections or panels that are separately prepared and then joined together using specialized adhesives. This segmentation allows each piece to be optimized for its specific area, eliminates the need for raised seams, and simplifies the manufacturing process by reducing labor-intensive sewing operations.
3Reliability
If conventional adhesive methods are used to attach leather, then attachment can be achieved, but the natural grain appearance of leather is diminished
Solution Approach 1:
The patent employs different adhesive application methods and material properties in different areas to preserve the natural grain appearance of the leather. By controlling the adhesive formulation, application thickness, and curing process locally, the natural texture and grain of the leather are maintained while ensuring reliable attachment to the substrate.
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
The solution enables a robust, aesthetically pleasing, and durable display of imagery and data within vehicle compartments with improved adhesion and appearance of leather, reducing labor costs and maintaining the natural grain appearance.
Implementation Method 1
A plurality of semiconductor-based, lighting devices are supported at the back surface of the panel. Each of the lighting devices includes at least one lighting element. Each of the lighting elements is individually addressable to control the luminous intensity of light emitted by the at least one lighting element.
Data Source
AI summary
A low-profile, backlit panel assembly and a controller for displaying images and/or data within a passenger compartment of a vehicle are provided. The assembly includes a substrate panel perforated with a two-dimensional array of closely-spaced holes. The panel is configured to be attached to a support structure of the vehicle. The assembly further includes a plurality of semiconductor-based, lighting devices supported at a back surface of the panel. Each of the lighting devices includes at least one lighting element. Each of the lighting elements is individually addressable by the controller to control luminous intensity of the light emitted by the at least one lighting element. Each of the lighting devices is aligned with one of the holes so that light emitted by each of the lighting devices travels through its hole to the passenger compartment in the form of a pixel of a two-dimensional image.