Multilayer Body Injection Molding for Integrated Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of decorated plastic components with integrated electronic functions is complex and expensive due to the need for additional production steps to integrate lighting elements and electronic components with conventional circuit boards.
Innovation Solution
A method for producing a multi-layer body with integrated decoration and electronic functions by connecting a decorative layer, carrier layer, and plastic layer in a single work step, allowing for the integration of lighting elements and electronic components without subsequent assembly, using injection molding with heat-activatable adhesives and optical auxiliary layers to control light guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional separate manufacturing steps are used to integrate electronic functions and decoration into plastic components, then functional integration is achieved, but production complexity and cost increase significantly
Solution Approach 1:
The patent combines the decorative layer, substrate layer, and plastic layer into a single integrated structure using injection molding. The decorative layer is applied to the substrate layer, and both are then co-molded with the plastic layer in one manufacturing step, eliminating the need for separate assembly operations and reducing production complexity while maintaining functional integration.
Solution Approach 2:
The substrate layer serves multiple functions simultaneously: it acts as a carrier for the decorative layer, provides structural support, and enables integration with electronic components. This multi-functional design reduces the number of separate components needed, thereby simplifying the overall production process.
2Illumination intensity
If multiple additional layers are integrated between plastic cover and light-emitting elements, then optical functions are improved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates optical auxiliary layers (such as diffusers and light guides) directly into the plastic layer during the injection molding process. This co-molding approach allows multiple optical functions to be achieved within a single manufacturing step, avoiding the need for separate lamination or assembly operations for each optical layer.
3Adaptability or versatility
If LED circuit board is connected to main circuit board using connectors, then electronic functionality is achieved, but assembly complexity and production time increase
Solution Approach 1:
The patent integrates the circuit board directly into the substrate layer, allowing electronic components to be mounted and connected in a single integrated structure. This eliminates the need for separate connector assembly steps between the LED circuit board and main circuit board, thereby reducing production time and assembly complexity.
4Adaptability or versatility
If decorative layer is applied after injection molding by lamination or printing, then design flexibility is maintained, but production time increases
Solution Approach 1:
The patent applies the decorative layer to the substrate layer before the injection molding process. This preliminary application allows the decorative layer to be permanently bonded to the substrate during molding, eliminating the need for post-molding lamination or printing operations and thereby reducing production time while maintaining design flexibility.
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 method simplifies and cost-reduces the production of multi-layer bodies with integrated decoration and lighting, creating a stable and durable product with defined layer relationships and efficient light management, eliminating the need for external circuit boards and additional assembly steps.
Implementation Method 1
one of the layers can, for example, be coated with a heat-activated adhesive that is activated under the pressure and temperature conditions of the injection molding process
Implementation Method 2
at least one optical auxiliary layer (3, 3'), in particular a reflection layer or absorption layer, is applied to the decorative layer (4) and/or the substrate layer (2) and/or the injection-molded plastic layer (7)
Data Source
Figure 1~3
Figure 4~7
Figure 8~11
AI summary
The invention relates to a method for producing a multilayer body, having the following steps: a) providing a support layer on which at least one lighting means, in particular an LED, is arranged; b) providing a decorative layer; and c) injecting a plastic layer onto the support layer and/or the decorative layer in an injection mold. The invention further relates to a multilayer body produced using such a method.