Vehicle Headliner Lighting Module for Uniform Reading Spotlights

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing vehicle headliners with integrated lighting modules struggle to provide a spotlighting function with sufficient intensity and uniformity for reading, especially when the lighting module is attached to the back side of the headliner, leading to aesthetic and safety concerns due to protruding components and inadequate light distribution.

Innovation Solution

A vehicle headliner with a lighting module attached to the back side, featuring a one-piece optics system with collimator lenses and a transparent sheet with diffusing areas, aligned to ensure precise positioning and minimize light losses, producing a concentrated and uniform spotlighting beam using standard LEDs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If the lighting module is attached to the back side of the headliner, then aesthetic appearance and safety are improved, but light intensity and uniformity are insufficient for spotlighting

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidlight intensity

Core Design Contradiction:

ShapeVSIllumination intensity

Solution Approach 1:

A transparent sheet with diffusing areas is introduced as an intermediary component between the LED light source and the headliner front surface. This diffuser sheet redistributes the light from multiple LEDs to create a uniform spotlighting effect while allowing the lighting module to remain hidden on the back side of the headliner.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Multiple standard LEDs are combined in a single lighting module attached to the back side of the headliner. By merging multiple light sources and using a diffusing sheet, the system achieves sufficient light intensity and uniformity for spotlighting while maintaining aesthetic appearance.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If standard LEDs are used as light source, then cost and availability are improved, but light intensity is insufficient for spotlighting function

Engineering Contradiction:

ImprovecostVSAvoidlight intensity

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

The lighting system is segmented into multiple individual standard LEDs rather than using a single high-intensity source. By dividing the lighting function across multiple affordable standard LEDs and using optical elements to combine and distribute their light, the system achieves sufficient intensity while maintaining low cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple standard LEDs are merged into a single lighting module with their light paths combined through collimator lenses and a diffusing sheet. This merging of multiple low-intensity sources creates a high-intensity uniform spotlighting beam adequate for reading.

Inventive Principle:

Principle #5Merging (Combining)

3Illumination intensity

If holes are provided in the headliner for light transmission, then light intensity is improved, but alignment precision is critical to avoid light losses

Engineering Contradiction:

Improvelight intensityVSAvoidalignment precision

Core Design Contradiction:

Illumination intensityVSManufacturing precision

Solution Approach 1:

The transparent diffusing sheet acts as an intermediary that tolerates minor misalignments between the LEDs, collimator lenses, and headliner holes. The diffuser redistributes light from each LED through its corresponding hole, maintaining intensity even with slight manufacturing variations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The optical parameters of the system are optimized by using collimator lenses with specific focal lengths and positioning them at precise distances from the LEDs. This parameter optimization ensures that light beams are properly directed through the holes with minimal losses.

Inventive Principle:

Principle #35Parameter changes

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

The solution provides a visually appealing and safer headliner with a spotlighting beam of sufficient intensity and uniformity, enhancing reading comfort while maintaining a smooth aesthetic appearance by ensuring alignment and efficient light transmission through carefully positioned components.

Implementation Method 1

The one piece optics comprises several collimator lenses, each of one being in correspondence with each of the spotlighting LEDs

Methodology Applied

Scientific EffectCollimation: Lens

Implementation Method 2

The transparent sheet has diffusing areas, each of them being in correspondence with a first spotlighting hole

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentEP4023499B1Vehicle headliner with an integrated lighting module having a spotlighting function and manufacturing process thereof

Publication Date: 2023.08.30 GRP ANTOLIN ING SA

Figure 1~2
Figure 3
Figure 4

AI summary

Vehicle headliner with an integrated lighting module having a spotlighting function and manufacturing process thereof. Particularly the lighting module is attached to the back side of the headliner which is configured to emit a quality spotlighting beam L4 and to have a good aesthetic appearance. The headliner mainly comprises a substrate, a positioner frame, a decorative lining and a transparent sheet having diffusing areas and the lighting module comprises a printed circuit board, several spotlighting LEDs connected to the printed circuit board and an one piece optics comprising several collimator lens.