Emergency Lamp Switch Symbol Visibility via Ink Segmentation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Emergency lamp switches face reduced symbol recognition during low light conditions due to blurring of symbols caused by light penetration, especially with the conventional manufacturing processes involving multiple paint layers and laser-cutting, which complicates rapid driver operation in emergency situations.

Innovation Solution

A method of manufacturing an emergency lamp switch by printing symbols on a film using multiple inks, where the symbol is transferred to the switch body through injection molding, improving visibility and recognition by controlling light penetration with specific ink placements and coatings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple paint layers and laser-cutting are used in conventional manufacturing, then symbol recognition is improved during daytime, but symbol recognition deteriorates during low light conditions due to light penetration through white regions

Engineering Contradiction:

Improvesymbol recognitionVSAvoidsymbol recognition in low light

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The symbol area is segmented into multiple functional layers: a white ink layer for symbol visibility, a black ink layer for light blocking, and a red ink layer for background color. This segmentation allows each layer to perform its specific function, preventing light penetration through the symbol area while maintaining visibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the emergency lamp switch are assigned different optical properties: the symbol area has light-blocking characteristics (black ink backing) while the non-symbol areas maintain light transmission (red ink only). This local differentiation ensures symbols remain visible and recognizable in low light conditions without compromising overall lamp functionality.

Inventive Principle:

Principle #3Local quality

2Illumination intensity

If multiple paint layers are applied sequentially, then symbol visibility is enhanced, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvesymbol visibilityVSAvoidmanufacturing process

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

Multiple painting operations are merged into a single printing process where all ink layers (white, black, red) are applied simultaneously or in optimized sequence on the film before injection molding. This consolidation reduces manufacturing steps, lowers complexity, and maintains the multi-layer optical structure necessary for symbol visibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The symbol pattern and multi-layer ink structure are prepared in advance on the film substrate before the injection molding process. This preliminary preparation allows the complex multi-layer structure to be created once during film fabrication, eliminating the need for multiple subsequent painting and drying cycles during emergency lamp switch manufacturing.

Inventive Principle:

Principle #10Preliminary action

3Illumination intensity

If light penetrates through the white region of the symbol printed area, then the emergency lamp switch provides good visibility during daytime, but symbol recognition is compromised during low light conditions

Engineering Contradiction:

Improvedaytime visibilityVSAvoidsymbol recognition

Core Design Contradiction:

Illumination intensityVSLoss of information

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

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

Enhances symbol recognition by preventing light from penetrating non-symbol areas, reducing manufacturing complexity and costs by eliminating the need for multiple paint layers and laser-cutting, thereby improving the switch's usability in low light conditions.

Implementation Method 1

printing a second ink of black color (e.g., or the like such as any dark color) on the back side of a first ink printed surface to prevent transmission of light

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 2

injection-molding an emergency lamp switch body on a symbol print surface of the film to transfer the symbol print surface to the emergency lamp switch body

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS10239242B2Method of manufacturing emergency lamp switch

Publication Date: 2019.03.26 HYUNDAI MOTOR CO LTD

AI summary

A method of manufacturing an emergency lamp switch is provided. The method includes printing a symbol on a film using inks of a plurality of colors and injection-molding an emergency lamp switch body on a symbol print surface of the film. The symbol print surface is transferred to the emergency lamp switch body and the film from the emergency lamp switch body is removed.