Plastic Cover Window Layer Structure for UV-Stable Vehicle Styling

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Solution Overview

Problem

Conventional vehicle window glasses with glass materials are limited in implementing various designs and colors due to manufacturing characteristics, and they face issues with light stability, adhesion deterioration, and fragility, especially when exposed to sunlight.

Innovation Solution

A cover window made of plastic, featuring a base material layer, a black layer, a print layer, and a coating layer, where the black layer is formed with dual injection and includes a notch to prevent intrusion, and the layers are composed of specific weight percentages of materials like polycarbonate resin, colored pigments, and light stabilizers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If glass material is used for conventional window glass, then transparency and durability are achieved, but various designs and colors cannot be implemented due to manufacturing characteristics

Engineering Contradiction:

Improvedesign varietyVSAvoidmanufacturing flexibility

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The window glass is divided into multiple functional layers: base material layer (glass), black layer (peripheral region), and print layer (design region). This segmentation allows each layer to be optimized independently - the base material maintains transparency and durability, while the print layer enables various designs and colors through plastic material properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining glass base material with plastic print layers. The glass provides structural integrity and transparency, while the plastic print layer enables color implementation and design flexibility, resolving the contradiction between durability and design variety.

Inventive Principle:

Principle #40Composite materials

2Illumination intensity

If black color is implemented through print on rear surface of glass, then aesthetic appearance is improved, but adhesion deterioration occurs due to sunlight exposure

Engineering Contradiction:

Improvelight stabilityVSAvoidadhesion stability

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

A boundary surface treatment layer is introduced between the black layer and the base material layer. This intermediary layer prevents direct contact between the black print and glass, eliminating the chemical reaction caused by sunlight exposure that leads to adhesion deterioration, while maintaining the aesthetic appearance and light stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If PC material is used for headlamp cover, then impact resistance is improved, but weatherability deteriorates due to poor UV resistance

Engineering Contradiction:

Improveimpact resistanceVSAvoidweatherability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The headlamp cover uses a composite structure with PC base material providing impact resistance, while a separate coating layer with UV stabilizers and light shielding agents provides weatherability. This allows each material to excel at its primary function without compromising the other.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coating layer contains UV stabilizers and light shielding agents that change the optical and chemical parameters of the surface, providing UV resistance and weatherability protection to the PC material which inherently lacks these properties.

Inventive Principle:

Principle #35Parameter changes

4Illumination intensity

If PMMA material is used for brake lamp cover, then transparency is improved, but fragility increases making it unsuitable for headlamp application

Engineering Contradiction:

ImprovetransparencyVSAvoidfragility

Core Design Contradiction:

Illumination intensityVSStrength

Solution Approach 1:

The invention combines PMMA's transparency advantage with PC's impact resistance by using PC as the base material layer and applying PMMA or other transparent materials as coating layers. This composite approach achieves both high transparency and durability required for headlamp covers.

Inventive Principle:

Principle #40Composite materials

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 enables the implementation of various designs and colors, improves light stability, prevents adhesion deterioration, and reduces the risk of breakage and discoloration, while also reducing manufacturing costs and enhancing safety.

Implementation Method 1

an excellent resin composition capable of shielding of the visible rays, and improving transmittance and refractive index for the infrared rays is needed

Methodology Applied

Scientific EffectUltraviolet absorption: Absorption (EM radiation)

Implementation Method 2

When the PC layer is exposed to the sunlight or an artificial light, bonding of polymers may be broken by the ultraviolet rays

Methodology Applied

Scientific EffectLight shielding: Absorption (EM radiation)

Data Source

PatentUS20250135855A1Cover window and manufacturing method for the same

Publication Date: 2025.05.01 SEOYON E HWA CO LTD

AI summary

Disclosed is a cover window using a plastic rather than a glass, and a method for manufacturing the same. The cover window includes: a base material layer formed of a transparent plastic material; a black layer stacked on one surface of the base material layer and formed along a periphery of the base material layer; a print layer stacked on another surface of the base material layer; and a coating layer stacked on one surface of the print layer.