Illuminated Automotive Trim Assembly With Low-Distortion Lightguide
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Solution Overview
Problem
Challenges arise in incorporating light accents into narrow automotive trim components due to tooling design and optical distortions caused by fixation features, which increase tool complexity and limit feasibility, especially in components with a skin and core material thickness greater than 4 mm.
Innovation Solution
The development of an automotive trim component with a lightguide assembly, a front cover composed of transparent/translucent resin and opaque resin, and a back cover acting as a carrier with a rib to support an electrical harness, formed using a multi-shot injection molding process, incorporating a metallic or chrome plating layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixation features are added to narrow trim components to support illumination elements, then the illumination function is achieved, but optical distortions occur and tool complexity increases
Solution Approach 1:
The patent combines the fixation features for illumination elements directly into the multi-shot molded part structure itself, merging the support function with the cosmetic cover. This integration eliminates the need for separate fixation components and reduces tool complexity while avoiding optical distortions that would result from separate attachment features.
Solution Approach 2:
The multi-shot molded part serves multiple functions simultaneously: it provides the cosmetic appearance (front cover), structural support (back cover), and fixation for illumination elements (integrated fixation features). This multi-functionality reduces the overall number of components and simplifies tooling requirements.
2Reliability
If material skin and core thicknesses are increased to meet molding requirements, then manufacturing reliability is improved, but the total inner thickness exceeds 4 mm which limits space for illumination elements
Solution Approach 1:
The patent utilizes the multi-shot molding process to create a layered structure where different material functions are stacked in the thickness dimension. The cosmetic cover and structural back cover are formed as separate shots with different optimal thicknesses, allowing each layer to be optimized independently while maintaining overall compactness within the 4 mm constraint.
Solution Approach 2:
Different regions of the part have different thickness requirements. The multi-shot process allows the cosmetic cover to have sufficient thickness for appearance quality while the back cover provides structural support with appropriate thickness, and illumination elements are positioned in regions where space is optimized for their specific requirements.
3Adaptability or versatility
If separate fixation features are added to the multi-shot part, then illumination elements can be secured, but tool feasibility is limited and manufacturing complexity increases
Solution Approach 1:
The fixation features are merged into the multi-shot molded part structure itself rather than being added as separate components. This integration maintains the ability to securely fix illumination elements while preserving tool feasibility and avoiding the manufacturing complexity that would result from separate fixation components.
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 minimizes optical distortions, reduces tool complexity, and optimizes space for illumination elements, providing a uniform appearance and efficient assembly process.
Implementation Method 1
the front cover is formed using a multi-shot injection molding process
Implementation Method 2
the metallic layer is a chrome or near-chrome plating applied to the opaque plateable resin via an electroplating deposition technique
Implementation Method 3
a lightguide assembly including a set of illumination elements configured to generate light and a lightguide for directing the generated light
Data Source
AI summary
Example components, methods of manufacturing, and/or the like are provided for an automotive trim component (100). In some embodiments, an automotive trim component (100) may include a lightguide assembly (128) including a set of illumination elements configured to generate light and a lightguide for directing the generated light; a front cover (104) including a combination of a transparent or translucent resin and an opaque resin; and a back cover (108) configured to act as a carrier for the lightguide assembly (128), the back cover (108) including an electrical harness (132) and a rib (136) disposed around at least a portion of the lightguide assembly (128), wherein the rib (136) is configured to contain and support the electrical harness (132).