Painted Composite MicroLED Components for Lightweight Vehicle Lighting
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Solution Overview
Problem
Existing vehicle components, such as hoods and taillights, face challenges in reducing weight while maintaining effective integration of microLEDs for lighting, as current methods do not efficiently combine lightweight polymer matrices with reinforcing fibers and microLEDs for structural and non-structural applications.
Innovation Solution
A painted component comprising a transparent layer with microLEDs embedded or attached, interconnected, and encapsulated with a transparent material, along with reinforcing fibers like carbon or glass fibers, and a painted layer with etched or masked portions to allow light transmission, utilizing conductive traces or ink for interconnects and a protective coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If vehicle components are made using polymer matrix to reduce weight, then weight is reduced, but structural strength and integration capability for microLEDs deteriorates
Solution Approach 1:
The patent uses a composite structure combining polymer matrix with reinforcing fibers (carbon fibers, glass fibers, basalt fibers, flax fibers, or hemp fibers) to create a lightweight yet strong component. This composite approach allows weight reduction while maintaining structural integrity and providing embedding capability for microLEDs.
2Adaptability or versatility
If microLEDs are integrated into polymer components, then lighting functionality is added, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated component: the polymer matrix provides structural support, reinforcing fibers enhance strength, microLEDs provide lighting functionality, and the clear coat provides protection and optical clarity. This consolidation reduces the number of separate parts and simplifies the overall manufacturing process.
Solution Approach 2:
The microLEDs are attached to or embedded in the polymer matrix before final curing and painting steps. This preliminary integration allows subsequent manufacturing steps (encapsulation, painting, clear coating) to proceed without disrupting the LED arrangement, simplifying the overall process.
3Shape
If painted layer is applied over microLEDs, then aesthetic appearance is improved, but light transmission is blocked
Solution Approach 1:
The painted layer is applied with local variations: fully painted areas provide aesthetic appearance and protection, while clear or etched portions at microLED locations allow light transmission. This spatially differentiated quality allows simultaneous achievement of aesthetic appearance and lighting functionality.
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 solution enables lightweight, structurally sound vehicle components with efficient light transmission and electrical connectivity, enhancing the integration of microLEDs within polymer matrices for various vehicular and non-vehicular applications while maintaining durability and aesthetic appeal.
Implementation Method 1
A plurality of microLEDs is at least one of attached to or embedded in the transparent layer
Implementation Method 2
An encapsulating material encapsulates the transparent layer, the plurality of microLEDs, and the plurality of interconnections
Implementation Method 3
A plurality of interconnects are made to the plurality of microLEDs; the interconnects are selected from a group consisting of conductive traces and conductive ink
Data Source
AI summary
A painted component including micro light emitting diodes (microLEDs) comprises a transparent layer including a first side and a second side. A plurality of microLEDs are at least one of attached to or embedded in the transparent layer adjacent to the first side of the transparent layer and plurality of interconnects are made to the plurality of microLEDs. An encapsulating material encapsulates the transparent layer, the plurality of microLEDs, and the plurality of interconnections. A painted layer on the second side of the transparent layer includes at least one of etched portions and masked portions arranged over the plurality of microLEDs.