Multizone Reflector Coating for Hidden Sensor Openings
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Solution Overview
Problem
Existing reflective surfaces in the automotive industry, used to reduce glare and accommodate sensors, often require transmissive openings that are aesthetically undesirable and increase production complexity.
Innovation Solution
A reflective surface with a discreet transflective region is created using a multi-layer structure comprising a transparent substrate, opaque and reflective layers, and a high refractive index layer, allowing for sensor placement while maintaining uniform appearance and reducing the visibility of the transmissive region.
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 aesthetic appearance deteriorates due to the visibility of the opening
Solution Approach 1:
The patent applies local quality by creating a multi-layer coating structure with spatially varying optical properties. The first coating layer has different optical characteristics than the second coating layer, allowing the sensor opening region to have tailored transmissive properties while the surrounding opaque region maintains its reflective appearance. This local differentiation enables the opening to be functional for sensors while minimizing aesthetic impact.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the optical properties (transmittance, reflectance) of different regions through controlled coating deposition. The first and second coating layers are applied with specific thicknesses and material compositions to achieve desired optical parameters. By varying these parameters across different regions (opaque vs. sensor opening), the patent achieves both functional sensor access and acceptable aesthetic appearance.
2Device complexity
If a simple opening is created for the sensor, then production complexity is reduced, but the visibility of the transmissive region increases
Solution Approach 1:
The patent employs composite materials by combining multiple coating layers with different optical properties. The first coating layer (with first optical properties) and second coating layer (with second optical properties) are deposited in sequence to create a composite structure. This composite approach allows precise control over the optical characteristics of the sensor opening region, reducing visibility while maintaining production feasibility through established multi-layer coating processes.
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 achieves a uniform aesthetic appearance by minimizing the difference in total reflectance and color reflectance between opaque and transflective regions, enabling simpler and cost-effective production without the need for large graded transitions.
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.