Vehicle Headliner Groove for Continuous Light Pipe
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Solution Overview
Problem
The existing methods for integrating light pipes into vehicle roof panels increase manufacturing complexity and mass, reducing fuel economy due to the need for multiple brackets and fasteners, which also segment the light emission and reduce visibility.
Innovation Solution
A headliner with a continuous groove around its periphery to house a light emitting material, eliminating the need for fasteners and bezels by molding the groove directly into the substrate, allowing the light emitting material to extend uninterrupted and flush with the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light pipes are secured to the bezel using brackets and fasteners, then the light pipe is supported, but the manufacturing complexity increases and mass increases
Solution Approach 1:
The groove for receiving the light pipe is integrated directly into the headliner substrate, merging the support structure with the headliner itself. This eliminates the need for separate brackets and fasteners, reducing manufacturing complexity while maintaining light pipe support.
Solution Approach 2:
The support function is extracted from separate components (brackets and fasteners) and incorporated into the headliner substrate through the molded groove. This simplifies the overall assembly by removing unnecessary intermediate components.
2Reliability
If brackets and fasteners are used to support the light pipe, then the light pipe is secured, but the mass of the roof panel and headliner increases
Solution Approach 1:
The support structure is merged with the headliner substrate through the integrated groove, eliminating the need for additional support components. This reduces the overall mass of the roof panel assembly while maintaining light pipe support.
3Reliability
If multiple brackets and fasteners are used, then the light pipe is secured, but fuel economy decreases
Solution Approach 1:
The support structure is integrated into the headliner substrate, reducing the total mass of the roof panel assembly. This mass reduction leads to improved fuel economy while maintaining light pipe support functionality.
4Reliability
If the light pipe is segmented by brackets, then the light pipe is supported, but the light emission is reduced and visibility is compromised
Solution Approach 1:
The continuous groove in the headliner substrate allows the light pipe to extend uninterrupted around the periphery, maintaining continuous light emission. This eliminates segmentation caused by brackets and fasteners, improving visibility while providing support.
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 reduces manufacturing complexity, minimizes mass, and enhances visibility by providing continuous and efficient light emission around the roof panel, improving fuel economy and aesthetic appeal.
Implementation Method 1
the substrate is configured to be heated on a second side to form the groove
Implementation Method 2
the groove is formed by a mandrel having an expandable end such that first and second portions of the mandrel are oppositely oriented and expand away from a center of the mandrel
Data Source
AI summary
A headliner for a vehicle includes a substrate that attaches to, and covers a roof panel, the substrate defining a groove on a first side formed around an entirety of a periphery of an area of the roof panel, wherein the groove is continuous around the periphery. A light emitting material is disposed within the groove formed in the substrate and is uninterrupted around the periphery within the groove.