Multizone Reflector With Hidden Sensor Opening for Uniform Appearance
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Solution Overview
Problem
Reflective surfaces in the automotive industry often require transmissive openings for sensors, leading to an undesirable aesthetic appearance due to visible openings and increased production complexity.
Innovation Solution
A multi-zone reflector with a discreet sensor opening region, utilizing layers such as chrome, silver alloys, and high refractive index materials to minimize the difference in reflectance and transmittance between opaque and transflective regions, creating a uniform appearance without the need for graded transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a transmissive opening is created in the reflective surface to accommodate the sensor, then the sensor can be positioned behind the reflective surface, but the opening becomes visible and provides an undesirable aesthetic appearance
Solution Approach 1:
The patent applies local quality by creating a multizone reflector where different regions have different optical properties. The reflector includes a first region with high reflectance and a second region with transmissive properties for sensor access. By locally modifying the optical characteristics of specific zones rather than the entire surface, the patent enables sensor positioning while maintaining aesthetic appearance in visible areas.
Solution Approach 2:
The patent utilizes color and reflectance changes to mask the transmissive opening. The multizone reflector employs multiple layers including reflective layers, absorptive layers, and dielectric layers that manipulate light reflection and absorption. This creates regions with different reflectance characteristics that can visually blend the sensor opening with the surrounding reflective surface, reducing the visibility of the transmissive region.
2Reliability
If the transmissive region is made larger to improve sensor operation, then sensor performance improves, but the visibility of the transmissive region increases
Solution Approach 1:
The patent divides the reflector into distinct zones with different optical properties. The second region provides sufficient transmissive area for reliable sensor operation, while the first region maintains high reflectance for aesthetic appearance. This local differentiation allows the transmissive region to be optimized for sensor performance without compromising the visual appearance of the overall reflector surface.
Solution Approach 2:
The patent addresses the visibility issue by manipulating light in multiple dimensions through layered structures. The multilayer construction includes reflective layers, absorptive layers, and dielectric layers that control light reflection, absorption, and transmission from different angles and paths. This dimensional approach to light manipulation allows the transmissive region to provide adequate sensor access while appearing less visible through optical engineering of the layered structure.
3Adaptability or versatility
If multiple layers with different optical properties are used to create the multizone reflector, then the aesthetic appearance and sensor functionality are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the reflector into multiple functional layers, each with specific optical properties. The structure includes a substrate, reflective layers, absorptive layers, and dielectric layers, where each layer performs a specific optical function. This segmentation allows independent optimization of each layer's properties to achieve the desired multizone optical characteristics while maintaining a systematic manufacturing approach.
Solution Approach 2:
The patent employs composite material structures combining different materials with complementary optical properties. The multilayer reflector integrates metallic reflective layers, absorptive materials, and dielectric materials to create a composite structure that achieves complex optical functionality. This composite approach enables precise control over reflectance and transmission properties in different zones while providing a unified manufacturable structure.
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 a reflective surface with a discreet transflective region, enhancing aesthetic appeal and simplifying production by reducing the visibility of the sensor opening and allowing for cost-effective high deposition rate material usage.
Implementation Method 1
The third layer may have a high refractive index and may be disposed in the first direction relative the first substrate
Implementation Method 2
The second layer may be disposed in the first direction relative the first layer and may be substantially reflective in the visible spectrum
Implementation Method 3
The first layer may be disposed in a first direction relative the first substrate and may be substantially opaque in a visible spectrum
Data Source
AI summary
A reflective member having transflective and substantially opaque regions is disclosed. The transflective region may serve as a sensor opening region. When viewing the member from a first direction, the difference between a total light reflectance of the member at the substantially opaque region and at the sensor opening region is less than five percent. Additionally, when viewing the member from the first direction, the difference between a color reflectance of the member at the substantially opaque region and at the sensor opening region is less than 5 delta C* units. A sensor disposed in a second direction of the sensor opening region of the member is operable to receive light through the member at the sensor opening region. The second direction is opposite the first direction.