Illuminated Vehicle Trim Structure for Complex Graphics at Lower Cost

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing illuminated vehicle trim parts with complex graphics are costly due to high scrap rates and complex manufacturing processes, particularly in creating illuminated front grilles with vehicle logos.

Innovation Solution

The illuminated trim part design incorporates a transparent carrier layer with opaque components and printed or painted layers, along with a foil, where the foil is used only in areas of high complexity, and light penetration is controlled through cut-outs or printed areas to achieve desired illumination effects, reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If multiple layer painting combined with laser removal of paint is used to provide complex graphics, then the graphics complexity is improved, but the manufacturing cost increases and scrap amount increases

Engineering Contradiction:

Improvegraphics complexityVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The trim part is divided into multiple zones with different illumination requirements. Complex graphics (e.g., logos) are segmented from simple graphical elements. Different manufacturing techniques are applied to different segments: foils with cut-outs for complex areas, painted layers with laser removal for simpler areas, reducing overall complexity and cost

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the trim part are assigned different levels of graphical complexity and illumination requirements. High-value foils with precise cut-outs are used only where complex graphics are needed (e.g., central logo areas), while simpler painted layers suffice for peripheral areas, optimizing material usage and manufacturing cost

Inventive Principle:

Principle #3Local quality

2Shape

If decorated foils with screen printing are used to provide complex shapes and colors, then the graphics quality is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvegraphics qualityVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

Instead of applying expensive foils with screen printing to the entire trim part, the technique is applied only partially to specific areas where complex graphics are required. This partial application maintains high graphics quality where needed while significantly reducing manufacturing costs

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The invention uses a combination of durable painted layers for base graphics and disposable foils only where high complexity is needed. The foils serve their purpose in specific high-value areas and can be replaced more easily than reworking entire painted surfaces, optimizing the balance between quality and cost

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If the foil is used in areas of high complexity only, then the manufacturing cost is reduced, but the illumination coverage may be limited

Engineering Contradiction:

Improvemanufacturing costVSAvoidillumination coverage

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The illumination system is segmented into multiple light sources positioned at different locations within the trim part. This allows light to penetrate through both foil-covered complex areas and painted layer areas, ensuring comprehensive illumination coverage across the entire trim part while maintaining cost efficiency through selective foil usage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The painted layers with laser removal serve dual functions: they provide the base graphical design and simultaneously act as additional illumination surfaces. This multi-functionality ensures that areas without foils still contribute to the overall illumination effect, maintaining comprehensive coverage while reducing foil usage

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach allows for cost-effective production of illuminated trim parts with complex graphics by minimizing the use of expensive foils and optimizing manufacturing steps, while maintaining effective illumination and durability.

Implementation Method 1

having at least one cut-out through which the light provided by the light source can penetrate

Methodology Applied

Scientific EffectLight penetration: Light

Data Source

PatentUS20250361999A1Illuminated trim part of or for a vehicle and method for producing such an illuminated trim part

Publication Date: 2025.11.27 HELLA SATURNUS SLOVENIJA PROIZVODNJA SVETLOBNE OPREME ZA MOTORNA IN DRUGA VOZILA D O O

AI summary

The present invention relates to an illuminated or illuminable trim part of or for a vehicle. The trim part includes a light source for providing light, a transparent or translucent carrier layer, and a foil. At least one opaque component is applied to the carrier layer or is integrated into the carrier layer, and/or at least one painted layer is applied to the carrier layer. The foil comprises printed areas and/or has at least one cut-out through which light provided by the light source can penetrate. Moreover, the present invention relates to a method for manufacturing such a trim part.