Fiber Composite Lighting Structure for Simplified Mass Production
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Solution Overview
Problem
Existing methods for equipping fiber composite vehicle components with a lighting function, such as those using electroluminescent coatings, are complex and time-consuming, requiring additional production steps and precise positioning of electrically conductive fibers, which complicates mass production.
Innovation Solution
A fiber composite component with a lighting function is achieved by integrating an electroluminescent lamp between two fiber layers within a polymer matrix, utilizing a thin electroluminescent film with insulation layers for simplified handling and processing, allowing for mass production via methods like resin transfer molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an electroluminescent coating is applied to the fiber composite via screen printing, then the fiber composite component achieves a lighting function, but the production process becomes complex and time-consuming due to additional drying steps and precise positioning requirements
Solution Approach 1:
The lighting function is segmented into a separate electroluminescent lamp component that can be independently manufactured and then integrated into the fiber composite structure. This separates the lighting function from the structural component, allowing each to be optimized independently and simplifying the overall production process.
Solution Approach 2:
The electroluminescent lamp is nested within the fiber composite structure by placing it between fiber layers during the composite manufacturing process. The lamp is embedded into the polymer matrix along with the fiber reinforcement, allowing the lighting component to be integrated without separate attachment steps.
2Adaptability or versatility
If an electroluminescent coating is applied to the fiber composite, then the component has illumination capability, but additional time-consuming production steps are required as the coating must dry before further processing
Solution Approach 1:
The electroluminescent lamp manufacturing and fiber composite manufacturing processes are merged into a single integrated process. The lamp is placed between fiber layers and both are cured together in the RTM or wet molding process, eliminating separate drying and attachment steps that would slow down production.
Solution Approach 2:
The electroluminescent lamp is prepared in advance with insulation layers attached during lamp manufacturing, so that when it is placed between fiber layers, no additional preparation or positioning steps are needed during composite production. The insulation layers are pre-applied and bonded to the lamp structure.
3Adaptability or versatility
If electrically conductive fibers are integrated into the fiber composite with electroluminescent coating, then the lighting function is achieved, but the exact positioning of fibers and coating must be ensured which entails high complexity
Solution Approach 1:
The electroluminescent function is extracted from the fiber composite structure and implemented as a separate lamp component. This eliminates the need for precise positioning of conductive fibers and coating layers relative to each other, as the lamp is a self-contained unit with internal electrical connections already established.
Solution Approach 2:
The electroluminescent lamp acts as an intermediary component between the power supply and the fiber composite structure. Instead of requiring direct electrical connections through conductive fibers positioned with high precision, the lamp provides a standardized interface that simplifies electrical integration.
4Reliability
If a thick electroluminescent lamp structure is used, then the lighting element is more robust, but the space requirement increases which is not desirable for vehicle components
Solution Approach 1:
The electroluminescent lamp uses thin film structures for the lighting element and insulation layers. The insulation layers are thin polymer films that provide electrical insulation and mechanical protection without adding significant thickness. This allows the lamp to be robust yet space-efficient, suitable for integration into vehicle components where space is limited.
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 enables a mechanically durable, mass-producible fiber composite component with a two-dimensional lighting effect, offering flexibility in design and configuration while maintaining a low space requirement and ensuring reliable attachment and electrical insulation.
Implementation Method 1
an electroluminescent lamp (30)... The lighting element preferably includes an EL film (electroluminescent film), which is notable for a particularly flat design and has a low space requirement
Implementation Method 2
The lighting element of the electroluminescent lamp also has a first and second insulation layer, which electrically insulate the lighting element with respect to the fiber layers
Data Source
AI summary
A fiber composite component with a lighting function includes a fiber reinforced unit with at least two fiber layers integrated into a plastics matrix, and an electroluminescent light having a light source arranged between two adjacent fiber layers, the light source including a first insulating layer and a second insulating layer which electrically insulate the light source from the two adjacent fiber layers.