Transparent Hood-Shaped Operating Element With Frame-Isolated Cover
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Solution Overview
Problem
Existing methods for producing transparent, hood-shaped control elements for motor vehicle human-machine interfaces face challenges with material durability and dimensional accuracy due to thermal and mechanical stresses, leading to detachment issues, especially when using glass or glass-like materials.
Innovation Solution
A method involving thermal shaping of translucent or transparent thermoplastics, applying an opaque layer for luminosity, and connecting a hood-shaped panel to a frame using ultrasonic welding, ensuring the panel rests on the carrier exclusively via the frame, thereby avoiding detachment and allowing for arbitrary design mimicking glass materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass or glass-like surfaces are used for control elements, then high-quality impression is achieved, but risk of injury and complex production with high weight occur
Solution Approach 1:
The patent uses transparent thermoplastic materials to copy the aesthetic appearance of glass surfaces, achieving the high-quality visual impression without the inherent dangers and manufacturing complexities of actual glass. The thermoplastic carrier is shaped to mimic glass-like transparency and surface properties.
Solution Approach 2:
The patent employs thermoplastic materials that are easier and cheaper to manufacture compared to glass, allowing for more accessible production while maintaining the desired visual appearance. The material can be processed using standard thermforming techniques.
2Ease of manufacture
If thermal shaping processes are used to produce control elements, then transparent surfaces are achieved, but dimensional accuracy and durability deteriorate due to thermal load and solidification behavior
Solution Approach 1:
The patent divides the control element into two separate components: a thermoplastic carrier that undergoes thermal shaping to achieve transparency, and a separate transparent panel (glass or thermoplastic) that is subsequently attached. This segmentation allows the carrier to be formed with standard thermforming processes while the panel provides the final precise, durable transparent surface.
Solution Approach 2:
The carrier is pre-formed through thermal shaping to achieve the basic transparent structure and aesthetic appearance. Subsequently, the transparent panel is attached to this pre-formed carrier, combining the ease of thermal forming with the precision and durability of the panel material.
3Ease of manufacture
If thermal shaping processes are used with transparent coating, then transparent surfaces are achieved, but detachment occurs at transition points due to thermal load and solidification behavior
Solution Approach 1:
The patent separates the transparent surface function into a distinct panel component that is attached to the carrier, rather than being integrated through thermal shaping. This prevents the detachment issues that occur at transition points when transparent coatings are thermally formed, as the panel maintains its integrity independently.
4Ease of manufacture
If back-injection film injection molding is used, then control elements are produced, but detachment problems occur at the edge area of the film
Solution Approach 1:
The patent uses a separate transparent panel attached to the carrier rather than integrated film injection molding. This eliminates the edge detachment problems inherent in back-injection film processes, as the panel is secured as a distinct component with proper edge support and attachment mechanisms.
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 durable, visually appealing control element with enhanced design freedom, preventing detachment and maintaining the integrity of the visible surface, even under temperature fluctuations and mechanical stress, while mimicking the appearance of glass with high material thickness and straight edges.
Implementation Method 1
The material connection of the frame to the carrier is preferably carried out by ultrasonic welding
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3
AI summary
The invention relates to an operating element (1) comprising: a carrier (4) made of a translucent or transparent first thermoplastic; an opaque layer (4a), preferably an opaque lacquer layer, which is applied in certain areas to a surface of the carrier (4) in order to define a luminous area (4b) when light is coupled into the carrier (4) by means of a translucent, preferably uncoated, partial area of the surface; wherein the opaque layer (4a) and the luminous area (4b) define a common viewing area (4c) facing the viewer when the operating element (1) is attached as intended; a hood-shaped aperture (2) made of a transparent second thermoplastic that overlaps the viewing area (4c), so that the viewing area (4c) is visible through the aperture (2) and forms an outer contact surface (2b) on its side facing away from the viewing area (4c);a frame (3) made of an opaque third thermoplastic, which is bonded to the hood-shaped aperture (2) and receives the hood-shaped aperture (2); wherein the frame (3) is bonded to the support (4); and an associated manufacturing process.