Vehicle Lighting Grille Assembly With Hidden LED Light Transmission
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Solution Overview
Problem
Conventional vehicle grills in electrified vehicles, such as electric and fuel cell vehicles, face reduced efficiency as they no longer serve a cooling function, necessitating a new design that incorporates LED lighting for aesthetic and functional purposes like autonomous travel indication, charging mode display, and welcome lights.
Innovation Solution
A lighting grill assembly featuring a grill cover with a black paint portion for masking, a light transmitting portion created by removing black paint, an inner lens with a deposited metal layer for enhanced light emission, and a diffusion paint portion to prevent hot spots, along with a method of manufacturing involving laser etching and specific paint applications to achieve desired lighting effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional grill is used in electrified vehicles, then the cooling function is no longer needed, but the grill structure becomes redundant and aesthetically unappealing
Solution Approach 1:
The grill is transformed into a multi-functional component that combines aesthetic design with active lighting functions. LED lights are integrated into the grill structure, allowing it to serve both as a decorative element and as a functional lighting system for various vehicle modes (autonomous driving, charging, welcome lights, etc.).
Solution Approach 2:
The patent utilizes different colored LEDs (red, green, blue, yellow) to indicate different vehicle states and functions. The color-changing capability allows the grill to communicate vehicle status information aesthetically while maintaining functional clarity.
2Shape
If black paint is applied to the grill cover for aesthetic purposes, then the appearance is improved, but light transmission is blocked
Solution Approach 1:
The black paint is selectively applied only to specific regions of the grill cover where aesthetic masking is desired, while leaving other regions unpainted or with different paint properties to allow light transmission. This creates zones with different optical properties within the same component.
Solution Approach 2:
The grill cover is divided into distinct functional zones: black painted portions for aesthetic masking and non-black portions for light transmission. This segmentation allows simultaneous achievement of aesthetic appearance and light transmission functionality.
3Illumination intensity
If LED lights are directly installed on the grill cover, then the lighting function is achieved, but hot spots appear and aesthetic quality deteriorates
Solution Approach 1:
An inner lens is introduced as an intermediary component between the LED light source and the external environment. The lens diffuses the light output, eliminating hot spots while maintaining aesthetic quality. The lens acts as a mediator that transforms the raw LED output into a visually pleasing light distribution.
Solution Approach 2:
The inner lens utilizes diffusion paint with light-diffusing properties similar to porous materials. The diffusion paint scatters light throughout the lens material, preventing concentrated hot spots and creating a uniform, aesthetically pleasing light emission pattern.
4Illumination intensity
If a metal layer is deposited on the inner lens for enhanced light emission, then luminance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical lighting structures with a simpler optical approach using metal layer deposition on the inner lens. The metal layer acts as a reflective or diffusive surface that enhances light emission through optical properties rather than mechanical complexity.
Solution Approach 2:
The inner lens becomes a composite structure combining the base lens material with a deposited metal layer. This composite construction provides enhanced luminance properties while maintaining a relatively simple overall manufacturing process through standard deposition techniques.
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 enhances the aesthetic appeal of vehicles by creating dynamic lighting designs, improves luminance, and prevents hot spots, thereby differentiating the exterior design and improving the overall lighting performance.
Implementation Method 1
The light transmitting portion and the fine pattern portion may be formed by removing the painted black paint and the deposited metal layer by laser etching
Implementation Method 2
a metal layer is deposited on a surface of the inner lens
Implementation Method 3
a light source configured to radiate light from a rear of the inner lens
Implementation Method 4
a diffusion paint portion is painted, using a diffusion paint, on a rear surface of the inner lens
Data Source
AI summary
Disclosed are a lighting grill assembly for a vehicle and a method of manufacturing the same, the lighting grill assembly for a vehicle a grill cover, a black paint portion painted using a black paint on a rear surface of the grill cover, and the black paint portion forming a light transmitting portion through which light passes by removing a part of the painted black paint, an inner lens spaced apart from the rear surface of the grill cover in a rearward direction, and a metal layer is deposited on a surface of the inner lens, and a light source configured to radiate light from a rear of the inner lens.