Vehicle Lighting Grille Assembly With Laser-Etched Light Patterns

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Solution Overview

Problem

The efficiency of vehicle grills in electrified vehicles, such as electric and fuel cell vehicles, is compromised due to the lack of a cooling function, necessitating a shift from traditional cooling-focused designs to designs that incorporate lighting and design elements.

Innovation Solution

A lighting grill assembly featuring a grill cover with black and clear paint portions, an inner lens with a metal layer, and a light source configuration that includes a light transmitting and fine pattern portion, formed through laser etching, to enhance lighting and design aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a conventional grill design is used for electrified vehicles, then the cooling function is no longer needed, but the grill efficiency and design purpose are compromised

Engineering Contradiction:

Improvegrill functionVSAvoidgrill design

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The grill assembly is designed to perform multiple functions: lighting (through LED units and light transmitting portions), display (through different lighting patterns indicating vehicle states), and aesthetic design. This transforms the conventional single-function cooling grill into a multi-functional component that maintains relevance in electrified vehicles without cooling systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Illumination intensity

If a lighting grill assembly is implemented, then design aesthetics and lighting function are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvelighting effectVSAvoidgrill structure

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The grill assembly is divided into distinct functional segments: grill cover with light transmitting portions, inner lenses, LED light sources, and housing. This segmentation allows each component to be optimized and manufactured separately, then assembled into the complete lighting grill system, managing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grill cover combines multiple materials and treatments: transparent or translucent material for light transmission, black paint portions for contrast and design, and clear paint portions for protection. This composite approach enables both aesthetic design and functional lighting properties to be achieved simultaneously.

Inventive Principle:

Principle #40Composite materials

3Shape

If black paint is applied on the grill cover, then design contrast is improved, but light transmission is blocked

Engineering Contradiction:

Improvedesign patternVSAvoidlight transmission

Core Design Contradiction:

ShapeVSIllumination intensity

Solution Approach 1:

The grill cover features localized black paint portions applied only in specific areas to create design patterns and contrast, while other areas remain transparent or translucent to allow light transmission. This local application of different properties (painted vs. unpainted regions) enables both aesthetic design and lighting function to coexist in the same component.

Inventive Principle:

Principle #3Local quality

4Manufacturing precision

If laser etching is used to form light transmitting portions, then precision and design flexibility are improved, but manufacturing time increases

Engineering Contradiction:

Improvelight transmitting portion accuracyVSAvoidmanufacturing cycle

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Traditional mechanical machining methods are replaced with laser etching technology to form light transmitting portions in the grill cover. This substitution enables precise control of light transmission patterns, complex design flexibility, and reduced tooling requirements, though it requires careful process optimization to manage manufacturing cycle time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 improves lighting efficiency and design aesthetics by allowing light to be emitted through a metal layer while preventing chemical reactions and enhancing luminance and design patterns, thus differentiating vehicle exteriors.

Implementation Method 1

a light source configured to radiate light from a rear of the inner lens

Methodology Applied

Scientific EffectLight Emitting Diode: Light Emitting Diode

Implementation Method 2

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

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

a metal layer is deposited on a surface of the inner lens

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS12565141B2Lighting grill assembly for vehicle

Publication Date: 2026.03.03 HYUNDAI MOBIS CO LTD

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.