PDMS Vehicle Lamp Layer Stack to Prevent Warping in Coating
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Solution Overview
Problem
The manufacturing of vehicle lamps using micro LED technology faces challenges with deformation such as warping or twisting due to the use of different binders in light-diffusing, fluorescent, and color filter layers, which increases processing costs and time, and makes it difficult to coat these layers with conventional coaters.
Innovation Solution
A vehicle lamp structure where the fluorescent film and color filter comprise polydimethylsiloxane (PDMS) with the same binder, allowing for direct coating without solvents or dispersants, and using the same material in the light-diffusing layer, fluorescent film, and color filter to resist deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different binders are used in light-diffusing layer, fluorescent layer, and color filter layer, then each layer can be optimized for its specific function, but the laminate deforms through warping or twisting during manufacturing
Solution Approach 1:
The patent applies homogeneity by using the same binder material (PDMS) across all three layers - light-diffusing layer, fluorescent layer, and color filter layer. This uniform material composition ensures consistent thermal and mechanical properties throughout the laminate, preventing differential expansion and contraction that cause warping and twisting during manufacturing processes.
2Ease of manufacture
If conventional coaters are used to coat layers with different binders, then various coating techniques can be applied, but the process becomes complex with increased processing time and costs
Solution Approach 1:
The patent implements universality by making the binder material identical across all layers, which enables a single type of coater to process all layers uniformly. This eliminates the need for multiple specialized coating equipment and processes, simplifying the manufacturing line and improving productivity while maintaining coating quality for each functional layer.
3Manufacturing precision
If solvents and dispersants are used in coating processes, then pigment dispersion is improved, but the viscosity decreases making it difficult to coat directly onto fluorescent layers
Solution Approach 1:
The patent changes the material parameters by using PDMS binder without solvents or dispersants. The PDMS provides inherent pigment dispersion capability through its molecular structure and surface properties, maintaining appropriate viscosity for direct coating while achieving uniform pigment distribution in the color filter layer without requiring additional chemical additives.
Data Source
AI summary
A vehicle lamp and a method for manufacturing a vehicle lamp. The vehicle lamp includes a lower substrate, a fluorescent film and a color filter stacked in this order. The fluorescent film and the color filter include polydimethylsiloxane (PDMS).