Offset-LED Illuminated Emblem Lens for Uniform Vehicle Branding
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Solution Overview
Problem
Existing illuminated emblem assemblies often produce radial illumination patterns that are not desired, leading to a need for improved homogeneity and luminance in illuminated displays, particularly for branding on vehicles.
Innovation Solution
The development of an illuminated emblem assembly featuring a multi-component outer lens with a light source offset from the illuminated area, utilizing multi-shot injection molding with black and clear PMMA, and incorporating a light-emitting diode (LED) assembly with a reflective coating and textured surfaces to enhance lighting distribution, along with a method for manufacturing this assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a typical light source is used to illuminate an emblem, then the emblem can be illuminated in dark conditions, but the illumination produces a radial pattern that is not desired and reduces homogeneity
Solution Approach 1:
The light source is intentionally positioned offset from the emblem surface rather than centered, creating an asymmetric illumination geometry. This asymmetric positioning, combined with the specific lens design, transforms the natural radial light distribution into a controlled pattern that achieves uniform illumination across the emblem surface.
Solution Approach 2:
A multi-component lens system acts as an intermediary between the light source and the emblem. The lens includes a first component with a light-entering surface and a second component with a light-exiting surface, which together reshape the light distribution. This intermediary optical system transforms the radial light pattern into a homogeneous illumination pattern on the emblem.
2Manufacturing precision
If a multi-component outer lens with offset light source is used, then illumination homogeneity is improved, but device complexity increases
Solution Approach 1:
The multi-component lens system integrates multiple optical functions into a single assembled unit. The first lens component and second lens component are positioned in sequence to collectively perform light shaping, redirection, and distribution functions, achieving complex illumination control through combined simpler elements.
Solution Approach 2:
The lens components are designed with specific geometric parameters including surface curvatures, thickness variations, and material refractive indices. By optimizing these parameters, the lens system controls light propagation to achieve homogeneous illumination while managing the complexity through precise parameter specification rather than mechanical complexity.
3Manufacturing precision
If the light source is offset from the illuminated area, then homogeneity is improved, but the light path becomes more complex
Solution Approach 1:
The offset light source configuration utilizes the third dimension (depth/distance) to achieve homogeneous illumination. Rather than attempting to create uniform illumination in a two-dimensional plane from a centered source, the solution moves the light source to a different position in three-dimensional space, allowing the lens system to distribute light evenly across the emblem surface through controlled light path geometry.
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 improved homogeneity and luminance in illuminated emblems, enhancing visual appearance and reducing manufacturing costs while maintaining a low-profile design suitable for vehicle body components.
Implementation Method 1
a multi-component outer lens having an exterior surface and an interior surface further comprising an externally visible area to be illuminated
Implementation Method 2
a reflective coating is applied to at least a portion of the interior surface of the outer lens
Implementation Method 3
at least a portion of the interior surface of the outer lens or the exterior surface of the inner lens is grained or textured
Implementation Method 4
a light-emitting diode (LED) assembly with a reflective coating and textured surfaces to enhance lighting distribution
Data Source
AI summary
An illuminated emblem assembly includes a multi-component outer lens having an exterior surface and an interior surface further comprising an externally visible area to be illuminated, an inner lens having an exterior surface and an interior surface, a printed circuit board assembly, a heat sink, a housing for the inner and outer lenses, and at least one light source, wherein the at least one light source is offset from the externally visible area to be illuminated. A method of manufacturing the illuminated emblem assembly includes injection molding the multi-component outer lens, providing the inner lens, providing the housing for the inner and outer lenses, providing the at least one light source, and assembling the inner and outer lenses and the at least one light source within the housing to obtain the illuminated emblem assembly.