Backlit Decorative Surface With Laser Perforations and Diffuser Film
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Backlit vehicle interior surfaces using non-transparent or translucent materials like leather face issues with adhesive visibility and non-uniform illumination due to perforations, leading to instability and aesthetic concerns, which are challenging to address in industrial series manufacturing.
Innovation Solution
A process where a film is first adhered to the rear face of the decorative material, and then perforations are laser-introduced through the material but not the film, stabilizing the structure and functioning as a diffuser for uniform illumination, using a latent reactive adhesive film that remains intact during laser treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to the rear face of the decorative material after introducing perforations, then the decorative material can be bonded to the diffuser or light guide, but adhesive penetrates into the perforations and becomes visible from the front side, creating an unattractive appearance
Solution Approach 1:
The film is adhesively bonded to the rear face of the decorative material BEFORE the perforations are introduced. This preliminary bonding action prevents adhesive from needing to be applied later through the perforations, thereby preventing adhesive penetration and visibility from the front side while still achieving the necessary bonding strength.
Solution Approach 2:
The bonding function is segmented into two separate components: the film provides the adhesive bonding function to the rear face, while the perforations provide the light transmission function. This segmentation allows each component to perform its function without interfering with the other, preventing adhesive visibility while maintaining bonding strength.
2Strength
If adhesive is applied to the rear face of the decorative material after introducing perforations, then bonding can be achieved, but the different amounts and distribution of adhesive in the perforations results in fluctuating light intensity and distribution
Solution Approach 1:
The film is bonded to the rear face before perforations are made, establishing a uniform bonding layer across the entire surface. This preliminary action ensures that adhesive is not distributed unevenly within perforations, thereby maintaining uniform light intensity and distribution while achieving adequate bonding strength.
3Illumination intensity
If a plurality of perforations is introduced into the decorative material in a specific pattern, then light can pass through to create backlighting, but the stability of the decorative material reduces and the material tends to warp
Solution Approach 1:
The film is adhesively bonded to the rear face of the decorative material before the perforations are introduced. This preliminary bonding provides structural support and stabilization to the material, preventing warping that would otherwise occur when multiple perforations are introduced for the backlighting effect.
4Illumination intensity
If the decorative material is perforated to allow light passage, then backlighting can be achieved, but the desired perforation pattern cannot be adhesively bonded to the light guide without interruptions
Solution Approach 1:
The bonding function is separated from the perforation function. The film provides continuous adhesive bonding across the entire rear face including over the perforations, while the perforations remain open for light transmission. This segmentation allows the perforation pattern to be maintained without interruptions in the bonding process.
Solution Approach 2:
The film is bonded to the rear face before the perforations are made, creating a continuous bonding layer that is not interrupted by the subsequent perforation process. This preliminary bonding action ensures manufacturing continuity while allowing the desired perforation pattern to be achieved for backlighting.
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 achieves optically appealing, reproducible, and uniform backlighting while preventing adhesive penetration into perforations and maintaining material stability, meeting the requirements of industrial series manufacturing.
Implementation Method 1
the perforations are introduced by means of a laser
Implementation Method 2
the film...functions as a diffuser for uniform illumination
Implementation Method 3
a film is adhesively bonded to the rear face of the decorative material
Data Source
AI summary
The invention relates to a planar decorative material (11) comprising perforations (12), for interior fittings, in particular for the automobile industry, which decorative material serves to be illuminated on the rearward face (13) thereof, by an illumination means (18), and allows a portion of the light from the illumination means (18) to pass from the rear face (13) of the decorative material (11), through the perforations (12), to the visible side (14) of the decorative material (11), wherein a film (20) is adhesively bonded to the rear face (13) of the decorative material (11) and the perforations (12) extend from the rear face (13) of the decorative material (11) as far as the visible side (14) thereof, but not through the film (20).The present invention also relates to a production method.