Illuminated Vehicle Emblem Lens Structure for Low-Energy Laser Welding
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Solution Overview
Problem
Existing illuminated vehicle emblems require powerful laser sources for welding opalescent polymers, leading to high production costs and energy inefficiency, with a risk of damaging the opalescent layer due to significant laser absorption.
Innovation Solution
An illuminated emblem design using a container body with a transparent polymer and an inner lens composed of a transparent and diffusing or opalescent layer, where through cavities or transparent portions allow laser welding without energy absorption, ensuring a robust coupling with the container body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If opalescent polymer materials are used for the inner lens to achieve light diffusion effect, then the visual appearance and light scattering performance are improved, but the laser welding process becomes difficult requiring high-power laser sources which increases production costs and energy consumption
Solution Approach 1:
The inner lens is divided into two distinct layers: a transparent polymer layer and an opalescent polymer layer. The transparent layer allows laser beams to pass through without significant absorption, while the opalescent layer provides the desired light diffusion effect. This segmentation resolves the contradiction by separating the optical function (light diffusion) from the welding function (laser transmission).
Solution Approach 2:
Different regions of the inner lens have different optical properties: the first layer is transparent to allow laser penetration, while the second layer is opalescent for light diffusion. This local differentiation of material properties enables both welding feasibility and aesthetic appearance without requiring high-power lasers throughout the entire component.
2Illumination intensity
If opalescent polymer materials are used for the inner lens to achieve light diffusion effect, then the visual appearance is improved, but the risk of damaging the opalescent layer during laser welding increases due to significant laser energy absorption
Solution Approach 1:
The inner lens is divided into two distinct layers: a transparent polymer layer and an opalescent polymer layer. The transparent layer allows laser beams to pass through without significant absorption, while the opalescent layer provides the desired light diffusion effect. This segmentation resolves the contradiction by separating the optical function (light diffusion) from the welding function (laser transmission).
Solution Approach 2:
The transparent polymer layer acts as an intermediary between the laser source and the opalescent layer. It allows the laser energy to pass through to reach the container body for welding while protecting the opalescent layer from direct laser exposure that would cause damage. This intermediary layer preserves the integrity of the opalescent material.
3Strength
If powerful laser sources are used for welding the opalescent inner lens to the container body, then the welding strength is improved, but the production costs and energy consumption increase
Solution Approach 1:
The inner lens is divided into two distinct layers: a transparent polymer layer and an opalescent polymer layer. The transparent layer allows laser beams to pass through without significant absorption, while the opalescent layer provides the desired light diffusion effect. This segmentation resolves the contradiction by separating the optical function (light diffusion) from the welding function (laser transmission).
Solution Approach 2:
The invention changes the optical parameters of the inner lens by using a transparent polymer with specific laser transmission properties. This parameter change allows the use of lower-power laser sources for welding, thereby reducing energy consumption and production costs while maintaining adequate welding joint strength.
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 design reduces the need for high-intensity laser sources, lowers production costs, maintains light diffusion quality, and provides a strong mechanical connection, while ensuring a distinctive visual effect.
Implementation Method 1
said first transparent layer allowing said laser beam to cross said inner lens without being absorbed
Implementation Method 2
a second layer (32) formed from an opalescent polymer material... which diffuse the light
Implementation Method 3
said at least one protrusion (36) intended to absorb said laser welding beam so as to melt at least partially
Implementation Method 4
melt at least partially said at least one protrusion (36) so as to form a joint with said inner lens (24)
Data Source
AI summary
An illuminated emblem for vehicles comprising a container body delimiting a cavity, a lighting device comprising at least one lighting source, at least partially housed in said cavity and configured to emit at least one light beam, an inner lens to cover at least partially said lighting source, the inner lens comprising a first transparent layer and a second diffusing or opalescent layer, said first transparent layer and second diffusing or opalescent layer being mutually integral. The container body comprises at least one protrusion which at least partially crosses the cavity and abuts against a fixing portion of the inner lens with which it forms a laser welding joint, said fixing portion being in contact with the first transparent layer or with the second diffusing or opalescent layer, an outer lens superimposed to cover at least partially the inner lens and to close at least partially the cavity.