Illuminated Vehicle Trim Part With Selective Foil Graphics
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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 detailed logos and patterns.
Innovation Solution
The solution involves dividing the trim part graphics into simple and complex areas, using opaque components and foils selectively, with foils applied only where complexity is high, and employing painted layers and light sources to achieve illumination effects, while minimizing costly foil usage.
Engineering Contradictions & Design Principles
Engineering 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 and scrap rate increase
Solution Approach 1:
The trim part surface is divided into multiple zones with different illumination requirements. Complex graphics (e.g., logos) are segmented from simple geometric patterns, allowing different manufacturing techniques to be applied to each segment. This reduces overall manufacturing complexity and cost while maintaining high graphics quality where needed.
Solution Approach 2:
Different surface treatments and illumination methods are applied to different areas of the trim part based on local requirements. High-value complex graphics receive premium treatment (foil with cut-outs), while simpler areas use more economical methods (painted layers), optimizing the balance between aesthetics and manufacturing cost.
2Shape
If decorated foils with screen printing are used to provide complex graphics, then the graphics quality is improved, but the manufacturing cost increases
Solution Approach 1:
The trim part is segmented into zones where foil application is only used for areas requiring high graphics quality (e.g., central logo areas), while other areas use simpler painted layers. This selective application reduces material costs and manufacturing complexity.
Solution Approach 2:
Foil with cut-outs is applied locally only to areas where high graphics quality is critical, such as manufacturer logos or emblematic patterns. Simpler painted layers are used for peripheral or less critical areas, optimizing the balance between visual impact and manufacturing cost.
3Illumination intensity
If foil is used for illuminated areas, then the illumination effect is improved, but the manufacturing cost increases
Solution Approach 1:
The trim part is divided into multiple illumination zones with different requirements. Foil material is used only in zones where high illumination quality is needed (e.g., logo areas), while simpler painted layers with integrated lighting are used in other zones, reducing overall material costs.
Solution Approach 2:
Foil with precise cut-outs is applied locally to areas requiring superior illumination effects, such as central emblems or key design elements. Peripheral areas or less critical zones use more economical painted layers, optimizing the balance between visual impact and manufacturing cost.
4Illumination intensity
If the complete trim part is covered with foil, then the illumination quality is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The trim part is segmented into multiple zones with different illumination requirements. Only specific zones (e.g., logo areas, central emblems) are covered with foil, while other zones use simpler painted layers. This reduces manufacturing complexity and material costs while maintaining high illumination quality where needed.
Solution Approach 2:
Foil application is restricted to local areas where high illumination quality is critical, such as manufacturer logos or emblematic patterns. The majority of the trim part surface uses more economical painted layers, significantly reducing manufacturing complexity and material costs while maintaining aesthetic appeal.
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 reduces manufacturing costs by limiting expensive foil use to complex areas, maintaining effective illumination with reduced production steps and improved durability against environmental factors.
Implementation Method 1
a light source for providing light, a transparent carrier layer, at least one opaque component applied to the carrier layer or integrated into the carrier layer, and/or at least one painted layer applied to the carrier layer, and a foil comprising printed areas, and/or having at least one cut-out through which the light provided by the light source can penetrate
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~4
AI summary
The present invention relates to an illuminated or illuminable trim part (121, 122, 123) of or for a vehicle (10), comprising - a light source (28) for providing light, - a transparent or translucent carrier layer (22), ∘ at least one opaque component (30) applied to the carrier layer (22) or integrated into the carrier layer (22), and/or ∘ at least one painted layer (44) applied to the carrier layer (22), - a foil (38) ∘ comprising printed areas (40), and/or ∘ having at least one cut-out (42) through which the light provided by the light source (28) can penetrate. Moreover, the present invention relates to a method for manufacturing such a trim part (121, 122, 123).