Electroluminescent Vehicle Trim with Embedded Conductor
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Solution Overview
Problem
Existing methods for making electrical connections to conductive paint layers in electroluminescent systems are inefficient, costly, and complex, particularly due to the use of expensive conductive epoxy and manual operations, which are challenging to automate and prone to heat damage from soldering.
Innovation Solution
A substrate with a conductor body embedded within it, where a conductive wire connects to an electrical power source, and a conductive bus bar paint layer is deposited over the exposed conductive surface, allowing for a robust and automated connection using standard materials and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive epoxy is used to make electrical connections to conductive paint layers, then electrical durability is enhanced, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent replaces expensive conductive epoxy with inexpensive conductive paint that can be applied in a sprayable form. The conductive paint serves as both the electrical connection medium and the protective coating, eliminating the need for separate epoxy application steps and reducing manufacturing complexity while maintaining adequate electrical durability for the application.
2Reliability
If manual operations are used to make electrical connections, then connection reliability is improved, but productivity decreases and automation is difficult
Solution Approach 1:
The conductive paint is applied in a manner that allows it to self-align and self-bond to the conductive paint layer without requiring precise manual placement. The sprayable formulation enables the paint to flow and conform to the contact patches automatically, creating reliable electrical connections through the inherent properties of the conductive material rather than through skilled manual manipulation.
Solution Approach 2:
The patent replaces manual mechanical operations with a spray deposition process. Instead of manually placing and securing conductive epoxy, the system uses aerosol spray technology to deposit conductive paint particles that automatically form electrical connections, enabling automation while maintaining connection reliability through the physical and chemical properties of the conductive material.
3Reliability
If soldering techniques are used to make electrical connections, then electrical connection is achieved, but the thin paint layer is damaged due to intense heat
Solution Approach 1:
The patent replaces thermal soldering processes with a cold spray deposition process. Conductive paint is applied as an aerosol that deposits and bonds to the contact patches without requiring high temperatures, thereby achieving reliable electrical connections while preserving the integrity of the thin paint layers that would be damaged by soldering heat.
4Reliability
If conductive epoxy is used to surround and bond wires to conductive paint, then electrical durability is enhanced, but manufacturing cost increases
Solution Approach 1:
The conductive paint serves multiple functions simultaneously: it provides the electrical connection medium, acts as the bonding agent to secure wires to the contact patches, and serves as the protective coating. This multi-functionality eliminates the need for separate conductive epoxy materials, reducing material costs while maintaining electrical durability through the combined properties of the conductive paint system.
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 solution enhances the reliability and reduces the cost and complexity of electrical connections, enabling efficient and durable connections suitable for vehicle trim components with electroluminescent lighting.
Implementation Method 1
Certain paint layers within the EL paint system are required to conduct electricity in order to act as a capacitor with a dielectric layer and a phosphor layer between the conductive layers
Implementation Method 2
Electroluminescent paint systems provide the ability to emit light from within painted surfaces of objects
Data Source
AI summary
A painted vehicle trim component such as a spoiler, side-view mirror housing, or other vehicle body part is provided with electroluminescent paint to emit light from its surface. The trim component includes a substrate having a mounting surface for attaching to the vehicle. A conductor body is at least partially embedded in the substrate to provide a conductive surface exposed externally of the substrate. A conductive wire is crimped to the conductor body and is adapted to connect to an electrical power source remotely from the vehicle trim component. A conductive bus bar paint layer is deposited over the substrate and onto the exposed conductive surface of the conductor body. A light-emitting paint layer deposited over the substrate is disposed relative to the conductive paint layer such that light is emitted when an electrical signal is received at the conductive wire.