Dual-Display Digital Cluster with Curved Plastic Lens
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Solution Overview
Problem
Digital dashboard clusters in vehicles face challenges with light reflections interfering with driver visibility due to the use of liquid crystal displays, particularly in high-end vehicles with three-dimensionally curved glass lenses, which are costly to manufacture and prone to deformation.
Innovation Solution
A dual-display digital cluster using a plastic lens with multiple curvatures, super retardation films, and a carrier bezel with a honeycomb structure, along with anti-reflection and anti-fingerprint coatings, to minimize light reflections and deformation, while reducing manufacturing costs through injection-induced residual stress minimization and snap-fit joint assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a three-dimensionally curved glass lens is used for the cluster, then light reflection is reduced and visibility is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent uses a plastic lens as a cost-effective copy substitute for the expensive glass lens. The plastic lens is molded with the same three-dimensionally curved surface shape as the glass lens to achieve identical optical performance in reducing light reflection, while being manufactured through injection molding which is significantly cheaper than glass processing
Solution Approach 2:
The patent changes the material parameter from glass to plastic while maintaining the geometric parameter of the three-dimensionally curved surface. This material substitution allows the same optical function to be achieved with a different manufacturing process that is more cost-effective and suitable for mass production
2Ease of manufacture
If a plastic lens is used instead of glass lens, then manufacturing cost is reduced, but the lens may deform under temperature and humidity variations
Solution Approach 1:
The patent applies a pre-molded high-gloss film to the plastic lens before final assembly. This film is pre-formed with the exact curvature needed and adhered to the plastic lens using adhesive tape, ensuring the optical surface maintains its shape and appearance even when the plastic lens itself may expand or contract due to environmental conditions
Solution Approach 2:
The patent creates a composite structure by combining the plastic lens with a high-gloss film layer. The plastic lens provides the base structure and optical curvature, while the film layer provides surface stability and optical quality, making the composite assembly more resistant to deformation from temperature and humidity changes
3Area of stationary object
If a large-area LCD is used in the digital cluster, then more information can be displayed, but light reflection interference increases
Solution Approach 1:
The patent employs a three-dimensionally curved surface on the lens covering the large-area LCD. This curvature causes incident light to reflect at various angles away from the driver's line of sight, thereby reducing reflection interference while maintaining the large display area needed for comprehensive information presentation
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 reduces light reflections and maintains optical performance, providing improved durability and visibility at a lower manufacturing cost, suitable for large-screen digital clusters in vehicles.
Implementation Method 1
The plastic lens may have a front surface including an anti-reflection (AR) coating layer
Implementation Method 2
super retardation films (SRFs) adhered to a plurality of positions on a rear surface of the plastic lens by using an optically clear adhesive (OCA)
Implementation Method 3
a plurality of liquid crystal displays (LCDs) each adhered to rear surfaces of the super retardation films by using an optically clear resin (OCR)
Data Source
AI summary
The present disclosure relates to a dual-display digital cluster for use with a vehicle, which includes a plastic lens having a plurality of curvatures, super retardation films (SRFs) adhered to a plurality of positions on a rear surface of the plastic lens by using an optically clear adhesive (OCA), a plurality of liquid crystal displays (LCDs) each adhered to rear surfaces of the super retardation films by using an optically clear resin (OCR), a carrier bezel configured to be assembled to a rear side of the plastic lens, to support the plurality of LCDs closely, and to prevent the plastic lens from being deformed, a rear cover assembled to a rear side of the carrier bezel, and at least one printed circuit board (PCB) disposed between the carrier bezel and the rear cover.