Luminous Vehicle Sunroof with Embedded Diodes and Collimating Optics
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Solution Overview
Problem
The existing luminous laminated glazed roofs for vehicles face challenges in reducing scrap rates and manufacturing costs while maintaining optical performance and robustness, with complexities in assembly and potential for aesthetic defects.
Innovation Solution
A luminous laminated glazed roof design featuring a laminated glazing system with a thin, flexible diode support and collimating optics integrated within the laminated glazing structure, utilizing a PVB interlayer and through or blind openings to minimize assembly risks and enhance light management, with a focus on reduced thickness and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light-emitting diodes are inserted into the laminated glazing to provide ambient light, then the optical performance is improved, but the manufacturing complexity and scrap rate increase
Solution Approach 1:
The patent merges the lighting function directly into the laminated glazing structure by integrating diodes into the lamination insert. The diodes are embedded within the PVB layer itself, combining the structural and lighting functions into a single integrated component, thereby reducing manufacturing complexity while maintaining ambient light functionality
Solution Approach 2:
The lamination insert serves multiple functions: it provides structural bonding between glass layers, optical clarity for visibility, and integrated lighting through embedded diodes. This multi-functionality reduces the need for separate lighting assemblies and simplifies the overall manufacturing process
2Ease of manufacture
If the lamination insert uses through openings for diode integration, then the assembly is simplified, but the risk of aesthetic defects and manufacturing issues increases
Solution Approach 1:
The patent extracts the diodes from traditional through-openings and relocates them into blind holes within the PVB lamination insert. This extraction from the external surface eliminates visibility of mounting hardware and potential aesthetic defects while maintaining simplified assembly through the blind hole integration method
Solution Approach 2:
The diodes are nested within blind holes created inside the PVB lamination insert itself. The mounting structure is embedded within the bulk material of the insert rather than requiring through-openings, creating a nested configuration that eliminates external mounting features and reduces aesthetic defects
3Length of moving object
If the glazing thickness is reduced to improve vehicle design, then the weight and compactness are improved, but the structural robustness and manufacturing reliability decrease
Solution Approach 1:
The patent changes the material parameters of the PVB lamination insert, specifically its thickness and mechanical properties, to compensate for reduced glass thickness. The PVB layer is designed with optimized thickness and enhanced mechanical characteristics to provide the necessary structural support and robustness that would otherwise require thicker glass
Solution Approach 2:
The patent uses composite material construction where the PVB lamination insert with embedded diodes and mounting features creates a composite structure. This composite approach allows thin glass layers to be bonded with a structurally robust PVB layer that provides both mechanical strength and integrated lighting functionality, achieving robustness without increasing overall thickness
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 results in a more robust, compact, and cost-effective luminous roof with improved optical performance and reduced manufacturing complexities, enhancing light distribution and reducing the risk of assembly defects.
Implementation Method 1
a (film) lamination insert (transparent), possibly clear, extra-clear or even tinted, in polymeric material, preferably thermoplastic and better still in polyvinyl butyral (PVB)
Implementation Method 2
Said lamination insert is provided between face FA and face FB with one or a set of M openings which are preferably through or forming blind holes
Data Source
Figure 1~1''
Figure 1a~1e
Figure 1'a~1'z
AI summary
The invention relates to a laminated glass sunroof of a vehicle (1000), comprising: - a first glass pane (1') forming an outer glass pane with first and second main faces (11', 12') referred to as face F1 and face F2 respectively, - a lamination insert (2) made of a polymer material with a thickness e1 of no more than 1.8mm, - a second glass pane (1) forming an inner glass pane with third and fourth main faces (11, 12) referred to as face F3 and face F4 respectively, where face F2 and face F3 constitute the inner faces of the laminated glass pane - a lamination insert with blind holes or through holes for housing diodes, and - optical collimators (5) between said diodes and face F3.