Carbon Trim Circuit Layer for Precise Multi-Surface Integration
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Solution Overview
Problem
The existing process for integrating functional elements into trim elements, such as door panels and dashboards, is time-consuming and complex, especially when multiple functional surfaces are involved, leading to potential errors in positioning and quality degradation.
Innovation Solution
A trim element with a functional layer made of carbon material that defines a pattern with conductive and non-conductive areas, allowing for the simple and reliable creation of electrical circuits on the support layer, which can be used to perform various vehicle-interaction functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If functional elements are integrated into the trim element using conventional methods (gluing circuits before applying decorative layer), then functional surfaces can be provided, but the process becomes time-consuming and complicated, especially when multiple functional surfaces are involved
Solution Approach 1:
The patent combines multiple functional elements and circuits directly into the support layer itself, eliminating the need for separate gluing operations. The support layer is designed to integrate multiple functional circuits simultaneously, reducing the number of discrete assembly steps and improving production efficiency while maintaining versatility.
Solution Approach 2:
The functional circuits are pre-integrated into the support layer during its manufacturing process, before the decorative layer is applied. This preliminary integration of functional elements into the support layer structure allows for more efficient subsequent assembly and reduces production time for multi-functional trim elements.
2Adaptability or versatility
If multiple functional elements are attached at different points of the support layer, then various functions can be implemented, but the positioning becomes complex and quality degrades due to incorrect positioning
Solution Approach 1:
The support layer is designed with specific local properties at different regions to accommodate various functional circuits. Each area of the support layer can be optimized for specific functional requirements, with predetermined positioning features that ensure accurate placement of different functional elements without complex alignment procedures.
Solution Approach 2:
The support layer is pre-configured with designated positions and alignment features for multiple functional circuits during its manufacturing process. This preliminary structuring of the support layer ensures that subsequent attachment of functional elements occurs at precise locations, maintaining high manufacturing precision even when multiple different functions are integrated.
Data Source
AI summary
A trim element includes at least one support layer having an inner face and an outer face and at least one functional layer of carbon material extending over at least part of the inner face and/or over at least part of the outer face of the support layer. A part of the functional layer defines a pattern having at least one conductive area of carbon material and at least one non-conductive area formed by a through-opening in the functional layer, the conductive area being powered by a current source electrically connected to the conductive area, the pattern forming at least a part of an electrical circuit arranged to perform a function.