Holographic Functional Layer on Plastic Lighting Component

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Solution Overview

Problem

Existing methods for applying holographic functional layers to plastic components in lighting devices are costly, inflexible, and do not effectively protect the thin and sensitive photopolymer layers, leading to suboptimal three-dimensional effects and increased risk of damage.

Innovation Solution

A method involving the formation of a laminar composite with a substrate and a functional layer, which is then welded or adhered to a plastic component using ultrasonic welding, ensuring the protection and durability of the thin layer while allowing for flexible orientation and heating to achieve a smooth, ripple-free surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the functional layer is applied directly to the plastic component, then the three-dimensional effect is enhanced, but the thin and sensitive photopolymer layer is at high risk of damage

Engineering Contradiction:

Improvethree-dimensional effectVSAvoiddamage risk of photopolymer layer

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies a composite material structure consisting of multiple layers: a substrate layer, a functional layer with hologram, and a protective layer. This composite structure protects the sensitive photopolymer layer while maintaining the three-dimensional holographic effect, resolving the contradiction between enhancement of visual effect and protection against damage.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional application methods are used, then the process is simple, but the production cost is high and flexibility is limited

Engineering Contradiction:

Improveapplication process simplicityVSAvoidproduction cost and flexibility

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent employs preliminary action by pre-assembling the functional layer on a substrate in a controlled environment before final application to the plastic component. This preliminary preparation enables better quality control, reduces waste, and allows for optimized production workflows, thereby reducing costs and increasing flexibility while maintaining process simplicity.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If the functional layer is made thinner to improve optical quality, then the three-dimensional effect is enhanced, but the layer becomes more sensitive and prone to damage

Engineering Contradiction:

Improveoptical qualityVSAvoidsensitivity to damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite structure where a thin functional layer with superior optical properties is combined with a substrate and protective layer. This composite approach allows the functional layer to remain thin for optimal three-dimensional effect while the additional layers provide mechanical strength and damage protection, resolving the contradiction between optical quality and damage sensitivity.

Inventive Principle:

Principle #40Composite materials

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 method allows for the economical and robust integration of holographic functional layers on plastic components, enhancing their durability and maintaining a high-quality, three-dimensional appearance while protecting the sensitive layers from damage.

Implementation Method 1

turning on a vacuum in the holding fixture and suctioning of the laminar composite by means of a suction area of the holding fixture

Methodology Applied

Scientific EffectVacuum suction: Vacuum

Implementation Method 2

joining at least areas of the laminar composite to the plastic component by means of a welding method or adhesive method

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS10414104B2Method for arranging a functional layer on a plastic component, and a composite made thereof

Publication Date: 2019.09.17 HELLA GMBH & CO KGAA

AI summary

A method for arranging a functional layer on a plastic component of a lighting device and a composite made of the plastic component and the functional layer, in particular a frame, an outer rim, a support frame, an inner lens, a retaining element, or the like is provided. The method includes that a film-like laminar composite is provided that has the functional layer and a substrate. The laminar composite is placed in a holding fixture. A vacuum is turned on in the holding fixture and suctioning of the laminar composite by means of a suction area of the holding fixture is performed. The plastic component is arranged on the laminar composite, and at least areas of the laminar composite are welded or bonded to the plastic component by means of a welding method or by means of an adhesive method.