Micro-Perforated Decorative Part With Micro-Optics for Sharp Display Output
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Solution Overview
Problem
Existing decorative parts in vehicle interiors face challenges in achieving seamless and uniform design surfaces with integrated actuation, information, and lighting functions, as light scattering within micro-perforations impairs luminance, edge sharpness, and color representation.
Innovation Solution
A shaped part with a decorative layer featuring micro-perforations and a micro-optical system comprising micro-structures that guide light from microLED displays through holes without scattering, ensuring excellent edge sharpness and luminance, and maintaining color representation, while preventing undesired changes to the decorative layer material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light is guided through holes in the decorative layer, then indications become visible on the front side, but light scattering at the interface impairs luminance and edge sharpness
Solution Approach 1:
A refractive index adaptation layer is introduced as an intermediary between the display and the decorative layer. This layer has a refractive index that is adapted to both the display material and the decorative layer material, serving as a transition medium that reduces refraction and light scattering at the interfaces, thereby improving both luminance and edge sharpness
Solution Approach 2:
The refractive index of the adaptation layer is specifically optimized to be between the refractive indices of the display and decorative layer. By changing this physical parameter (refractive index) of the intermediate layer, the optical performance is improved to reduce light scattering while maintaining efficient light guidance
2Illumination intensity
If holes are filled with liquid material to guide light, then light scattering is reduced, but the decorative layer material undergoes undesired changes
Solution Approach 1:
Instead of using permanent liquid filler materials that cause stability issues, the patent employs a solid adaptation layer that can be easily applied and removed. This solid layer provides the necessary optical function without the long-term stability problems associated with liquid materials that interact with the decorative layer
Solution Approach 2:
The patent replaces the liquid filler approach with a solid adaptation layer approach. This substitution eliminates the need for liquid materials that can cause chemical or physical changes to the decorative layer, while still achieving the desired light guidance function through refractive index adaptation
3Shape
If micro-perforation is used to integrate display, then design surface appears seamless when inactive, but light scattering impairs color representation
Solution Approach 1:
The refractive index adaptation layer serves as an intermediary that optimizes optical transmission through the micro-perforation. By matching refractive indices, it minimizes light scattering and interference, preserving the original colors emitted by the display while maintaining the seamless appearance when inactive
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 provides efficient light guidance, enhancing the visibility of indications with improved edge sharpness and luminance, maintaining color representation, and preventing material changes, thus achieving a seamless design surface that only reveals indications when active.
Implementation Method 1
an optical system by means of which visible light emanating from the display is guided from the rear side of the decorative layer through the holes to the front side of the decorative layer
Implementation Method 2
Each micro-structure is associated with a microLED and is arranged and designed such that it guides the light emanating from the microLED associated therewith through the hole associated therewith to the front side of the decorative layer
Data Source
AI summary
A shaped part comprising a decorative layer having a front/visible side, a rear/opposite side and a micro-perforation (plurality of through holes), The holes each extend in a straight line between the rear side and the front side. An optical system enables an indicator unit comprising a display on the rear side to be visibly displayed through the micro-perforation of the shaped part. The display is a microLED display, the pixels of which are formed by microLEDs, and the optical system is a micro-optical system having micro-structures, wherein each micro-structure extends from the rear side of the decorative layer into a hole associated therewith in the micro-perforation in the decorative layer. Each micro-structure is associated with a microLED and is arranged and designed such that it guides the light emanating from the microLED associated therewith through the hole associated therewith to the front side of the decorative layer.