Composite MicroLED Task Lighting With Hidden Optics Integration
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Solution Overview
Problem
Conventional task lighting systems in vehicles often have a styling mismatch when used with partially transparent structural composites, as the lighting components are visible and may not be visually appealing.
Innovation Solution
A structural composite with hidden and encapsulated microLED task lighting and molded-in optics is developed, where reinforcing fibers are used to conceal the microLEDs and traces, and a second polymer resin with integrated lenses is used to encapsulate the components, creating a visually cohesive and aesthetically pleasing lighting system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional task lighting systems are used with partially transparent structural composites, then the lighting function is provided, but the lighting components are visible and create a styling mismatch
Solution Approach 1:
The microLEDs, traces, and cables are nested within the structural composite itself. The lighting components are embedded in cavities formed within the composite material, allowing the structural component to serve dual purposes as both load-bearing element and lighting housing, eliminating visible external lighting components
Solution Approach 2:
The lighting system is merged with the structural composite by integrating microLEDs, traces, and optical elements directly into the composite material. The structural composite becomes the housing, mounting structure, and optical guide all in one, creating a seamless integration that eliminates styling mismatches
2Shape
If microLEDs and traces are embedded in structural composite, then visual appearance is improved, but thermal management becomes challenging
Solution Approach 1:
A thermally conductive intermediary material is introduced between the microLEDs and the structural composite. This intermediary layer acts as a thermal bridge, efficiently conducting heat away from the microLEDs while maintaining the optical and structural integrity of the composite, thus solving the thermal management challenge without compromising visual appearance
3Shape
If reinforcing fibers are used to conceal lighting components, then visual coherence is achieved, but light transmission is blocked
Solution Approach 1:
The structural composite is designed with spatially varying properties: regions with reinforcing fibers for structural strength and visual coherence, and localized fiber-free cavities or channels for light transmission. The fibers are strategically positioned to conceal lighting components while leaving optical pathways clear, achieving both visual coherence and light transmission through local material property variation
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 effectively integrates task lighting into structural composites, providing a visually appealing and functional lighting system that enhances the interior design of vehicles while maintaining the structural integrity and weight reduction benefits of composite materials.
Implementation Method 1
The structural composite, the M sets of traces, the N sets of microLEDs, a portion of the one or more cables are encapsulated in a second polymer resin
Implementation Method 2
The second polymer resin includes an integrated lens adjacent to the N sets of microLEDs
Implementation Method 3
N thermally conductive stacks are in thermal contact with the N sets of microLEDs and encapsulated in the second polymer resin
Implementation Method 4
N sets of microLEDs are arranged on the structural composite and connected to the M sets of traces
Implementation Method 5
N sets of microLEDs are arranged on the structural composite and connected to the M sets of traces
Implementation Method 6
The reinforcing fiber acts as a heat sink for the N microLEDs
Data Source
AI summary
A composite structure includes a structural composite including a plurality of reinforcing fibers encapsulated in a first polymer resin. M sets of traces are arranged on the structural composite. N sets of microLEDs are arranged on the structural composite and connected to the M sets of traces, respectively, where M and N are integers greater than zero. One or more cables are connected to the M sets of traces. The structural composite, the M sets of traces, the N sets of microLEDs, a portion of the one or more cables are encapsulated in a second polymer resin. The second polymer resin includes an integrated lens adjacent to the N sets of microLEDs.