3D-Printed Glazing Base With Flocking for Low-Reflection ADAS Mounting
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Solution Overview
Problem
Existing methods for manufacturing glazing units with anti-reflective properties for vehicle driving assistance systems are unsuitable for small-batch production due to complexity and cost, particularly when plastic injection molding is required, and 3D printing cannot produce the necessary surface textures with high precision, while paint application raises environmental and health concerns.
Innovation Solution
A method involving three-dimensional printing of a base for the glazing unit, followed by the application of a flocking with electrostatically charged fibers to reduce light reflection, using a double-sided adhesive film for easy application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If plastic injection molding is used to manufacture the base with anti-reflective properties, then manufacturing precision and anti-reflective performance are improved, but device complexity and manufacturing cost increase due to complex mold requirements
Solution Approach 1:
The patent separates the base manufacturing from the anti-reflective coating application. The base is manufactured using simple 3D printing, while the anti-reflective property is added through a separate flocking coating process. This segmentation allows simple manufacturing to achieve high precision anti-reflective surfaces without complex molds.
Solution Approach 2:
The patent uses composite construction by combining the printed base material with a flocking coating layer. The flocking material (fibers or powder) is applied to the base surface to create the anti-reflective effect, forming a composite structure that achieves high manufacturing precision without requiring complex molding processes.
2Device complexity
If 3D printing is used to manufacture the base, then device complexity and manufacturing cost are reduced, but manufacturing precision of surface textures deteriorates
Solution Approach 1:
The patent divides the manufacturing process into two independent stages: first, creating the base geometry using simple 3D printing; second, applying the anti-reflective flocking coating to achieve the required surface precision. This segmentation allows each process to be optimized independently, maintaining simplicity while achieving precision.
Solution Approach 2:
The flocking coating acts as an intermediary layer that transforms the low-precision 3D printed surface into a high-precision anti-reflective surface. The coating material fills in surface imperfections and provides the necessary optical properties without requiring the underlying 3D printing process to achieve high precision.
3Object-affected harmful factors
If paint is applied to achieve anti-reflective properties, then anti-reflective performance is improved, but environmental harm and manufacturing complexity increase due to paint booth requirements
Solution Approach 1:
The patent uses black flocking material that absorbs light through its color properties and fibrous structure, achieving anti-reflective performance without traditional reflective paints. The black color and fiber geometry work together to minimize light reflection while avoiding the environmental issues associated with paint application.
Solution Approach 2:
The flocking coating creates a porous, fibrous surface structure that traps and absorbs light, preventing reflection. This porous material approach achieves the same optical effect as paint but without the environmental harm, as the fibers can be applied using electrostatic deposition or adhesive methods without requiring paint booths.
4Manufacturing precision
If traditional manufacturing methods are used for glazing units, then manufacturing precision is improved, but productivity decreases due to long production times and inability to produce individual units
Solution Approach 1:
The patent changes the manufacturing parameters from batch production with long cycles to rapid 3D printing with short production times. The additive manufacturing process allows individual glazing units to be produced quickly on-demand, maintaining precision while dramatically improving productivity for small batches and custom units.
Solution Approach 2:
The base is pre-manufactured using 3D printing with integrated mounting features and shutter locations, allowing rapid assembly to the glazing element. This preliminary preparation of the base component enables quick production and installation of individual glazing units without lengthy traditional manufacturing cycles.
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
Enables quick and cost-effective production of small batches or individual glazing units with improved anti-reflective properties, minimizing downtime for vehicle modifications and enhancing image quality for driver assistance systems.
Implementation Method 1
a step of depositing a flocking comprising fibers, preferably black, on said sealing location
Implementation Method 2
The walls are made from a material that reduces light reflection or are coated with a material that has anti-reflective properties
Implementation Method 3
a step of depositing a flocking comprising fibers, preferably black, on said sealing location
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a method for manufacturing a glazing unit comprising a glazed element and a base (5) intended for a driving assistance system of a vehicle, said base (5) having means for attaching said light sensor and a sealing location (52), the method comprising the following successive steps: - a step of obtaining said base (5) by three-dimensional printing; - then a step of depositing flocking (4) comprising fibres on said sealing location (52); and - then a step of attaching said base (5) to said glazed element.