Automotive Illuminated Panel Structure Without Air Gaps
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Solution Overview
Problem
Existing illuminated panel structures for vehicles, particularly those covering radar sensors, face challenges in maintaining uniform luminance and reliability over time, often requiring complex structures with air gaps that can degrade and are not suitable for larger panels or interior use without impairing sensor operation.
Innovation Solution
A multi-layer panel structure with a light guide layer and continuous, lower refractive index layers on both surfaces, eliminating the need for air gaps and ensuring homogeneous illumination, while being transparent to radio waves and durable enough to protect radar sensors without affecting their function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air gaps are used between layers to maintain illumination function, then light leakage is prevented, but the structure becomes complex and reliability degrades over time
Solution Approach 1:
The invention extracts and eliminates the air gap layer from the multi-layer structure, replacing it with a continuous second layer that has appropriate optical properties. This removes the complex interface between air and solid materials while maintaining the light guiding and outcoupling functions through proper refractive index selection in the continuous layer.
Solution Approach 2:
The invention merges the functions of multiple separate layers (including the air gap) into a continuous second layer. This continuous layer combines the protective, optical, and structural functions that were previously distributed across multiple discrete layers with air gaps, simplifying the overall structure while maintaining reliability.
2Illumination intensity
If discontinuous layers are used to allow light outcoupling, then illumination is achieved, but light leakage occurs and uniform luminance is not maintained
Solution Approach 1:
The invention applies local quality by creating specific optical outcoupling zones within the continuous second layer. Rather than making the entire layer discontinuous, localized regions or patterns are designed to allow light outcoupling while the rest of the continuous layer prevents light leakage and maintains uniform luminance across the panel surface.
Solution Approach 2:
The invention changes the optical parameters (refractive index, thickness, material composition) of the continuous second layer to achieve optimal light outcoupling performance. By carefully selecting and tuning these parameters, the layer can maintain continuity for preventing light leakage while enabling sufficient light extraction for uniform illumination.
3Ease of manufacture
If multiple separate layers with air gaps are used, then light outcoupling is enabled, but manufacturing complexity increases and assembly becomes difficult
Solution Approach 1:
The invention merges multiple separate layers and air gaps into a single continuous second layer, reducing the total number of components that need to be manufactured and assembled. This integration simplifies both the manufacturing process and final assembly while maintaining the necessary optical functions through proper material selection and layer design.
4Reliability
If the panel structure is made transparent to radio waves with uniform thickness, then sensor function is maintained, but decorative flexibility is limited
Solution Approach 1:
The invention segments the panel into multiple functional layers, each with specific properties. The first layer (light guide) and second layer (continuous layer) can be designed with different optical and mechanical properties, allowing the overall structure to maintain radio wave transparency while enabling diverse decorative designs through variations in layer composition, thickness, and optical elements.
Solution Approach 2:
The invention uses composite material structures where the first layer and second layer are made from different materials with complementary properties. This allows optimization of each layer for its specific function (light guiding, outcoupling, radio wave transparency) while combining them to achieve both sensor compatibility and decorative versatility.
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 reliable, uniform, and durable illuminated panel structure that maintains sensor functionality and aesthetic appeal by preventing light leakage and ensuring continuous illumination, suitable for both decorative and protective applications on vehicles.
Implementation Method 1
a first layer of an optically transparent material adapted to serve as a light guide, the first layer having an upper surface and a lower surface and edges and being configured to receive light from at least one light source via at least an edge or the upper or lower surface
Implementation Method 2
the first layer further comprising at least one optical element for outcoupling light at least from an upper surface of the first layer
Implementation Method 3
the upper and lower second layers being of a second material having a refractive index lower than the first layer
Implementation Method 4
By providing continuous layers of a lower refractive index on the first layer, light leakage from the light guide is prevented
Implementation Method 5
which provides a uniform and homogenous luminance that does not degrade with time... substantially transparent to radio waves
Data Source
AI summary
A multi-layer panel structure for a vehicle is provided, and includes a first layer of an optically transparent material adapted to serve as a light guide. The first layer has an upper surface., a lower surface, and edges, and is configured to receive light from at least one light source via at least one edge. The first layer further includes at least one optical element for outcoupling light at least from an upper surface of the first layer. The panel structure further includes an upper second layer disposed on the upper surface of the first layer, and a lower second layer disposed on the lower surface of the first layer. Each are arranged to cover the whole of the upper and lower surface of the first layer in an uninterrupted, continuous fashion. Both are of a second optically transparent material having a refractive index lower than the first layer.