Perforated Trim Assembly with Light-Transmitting Polymer Infill
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Solution Overview
Problem
Existing lighted trim assemblies for motor vehicles and buildings lack a durable, aesthetically pleasing, and efficient method to create illuminated designs using perforated members that can accurately form letters, numbers, or patterns without the need for separate punching or relocation of non-perforated sections.
Innovation Solution
A perforated metal or polymer trim member with a light-transmitting material, featuring a combination of holes and shallow depressions that can be formed through stamping, chemical etching, or other processes, allowing for backlit illumination and precise design elements, such as letters or numbers, with the option to infill holes with transparent or colored polymer materials for enhanced illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate punching or relocation of non-perforated sections is used to form designs, then design flexibility is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines the formation of holes and design elements (letters, numbers, patterns) into a single integrated stamping operation. The stamping die directly creates both the perforations and the design features in one step, eliminating the need for separate punching and relocation operations. This merging of operations reduces manufacturing complexity while maintaining design flexibility through the capability to stamp various designs.
Solution Approach 2:
The stamping operation performs preliminary action by forming both the holes and the design elements simultaneously during the initial manufacturing step. The non-perforated sections are not relocated afterward but are instead positioned correctly during the stamping process itself, reducing subsequent manufacturing steps and complexity.
2Strength
If holes are made visible or large for structural reasons, then structural integrity is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The patent applies local quality by varying the size, shape, and distribution of holes in different regions of the trim member. Holes are made small and closely spaced in areas where aesthetic appearance is critical, creating a uniform lighted effect. In areas requiring greater structural integrity, the hole pattern can be adjusted to provide adequate strength while maintaining the overall aesthetic. This localized variation allows simultaneous optimization of both structural integrity and appearance.
Solution Approach 2:
The patent uses light transmission and color effects to mask the visibility of holes. When backlit, the holes create a uniform illuminated appearance that hides individual hole structures. The use of colored materials or coatings can further enhance this effect, making the holes imperceptible while maintaining structural integrity through appropriate hole sizing and distribution.
3Manufacturing precision
If holes are closely spaced to form designs, then design precision is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent replaces complex multi-step mechanical operations with a single stamping process. The stamping die incorporates the design pattern directly, allowing closely spaced holes and design elements to be formed in one operation. This substitution of a simplified mechanical process for a complex multi-step process reduces manufacturing difficulty while achieving high design precision through the stamped pattern.
Solution Approach 2:
The patent optimizes hole size, spacing, and distribution parameters to achieve the desired design precision while maintaining manufacturability. By carefully selecting parameters such as hole diameter (sufficiently small and closely spaced), spacing (to provide uniform illumination), and arrangement (to form designs), the patent achieves high precision designs that are still amenable to standard stamping 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 provides a visually appealing, uniformly lit, and structurally robust trim assembly that accurately displays designs without visible holes at normal viewing distances, offering flexibility in material choice and manufacturing processes while ensuring durability and water resistance.
Implementation Method 1
a light source, the light from which is transmitted through the openings in the item
Data Source
AI summary
A lighted assembly includes a perforated member having a plurality of relatively small openings therethrough. The openings are arranged to provide areas forming letters, designs, or the like. A light source may be positioned adjacent the perforated member whereby light from the light source travels through the openings to form illuminated letters, designs or the like. The perforations may be filled with a light-transmitting polymer material. The light source may comprise an LED and a light guide that distributes light along a lower side of the perforated member. The light source may be positioned in a waterproof housing that is sealed to the perforated member.