Automotive Plastic Glazing With Integrated Lighting to Cut Assembly Complexity

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Solution Overview

Problem

Conventional vehicle lighting systems are complex and costly due to numerous separate components, which increases the weight and manufacturing complexity of vehicles, and recent trends to add more lights for aesthetic and utility purposes exacerbate these issues.

Innovation Solution

The integration of a light unit within a one-piece molded plastic glazing component for vehicle windows, using multi-shot injection molding techniques to combine clear and colored thermoplastic polymers, with the light unit being securely attached via integrated fasteners or adhesives, reducing the number of separate components and enhancing manufacturing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional separate light assemblies are used, then lighting functions are achieved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvenumber of separate componentsVSAvoidlighting function

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent combines the light assembly with the window glazing into a single integrated unit. The light emitting elements are mounted directly on the window structure, eliminating the need for separate light housings and mounting brackets. This merging reduces the number of components while maintaining all necessary lighting functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The window structure serves multiple functions: it provides the structural window function and simultaneously serves as the mounting structure and housing for the light assembly. The window glazing acts as both the transparent panel and the light diffuser, eliminating the need for separate light housing components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Weight of moving object

If multiple separate light components are used, then various lighting functions are achieved, but vehicle weight increases

Engineering Contradiction:

Improvevehicle weightVSAvoidlighting functions

Core Design Contradiction:

Weight of moving objectVSAdaptability or versatility

Solution Approach 1:

The light assembly is merged with the window structure, eliminating redundant structural components. The window frame and mounting structure are combined into a single integrated unit, reducing the total material used and consequently the weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the light emitting elements from traditional bulky light assemblies and mounts them directly on the window structure. This removes unnecessary housing material while preserving the lighting function, thereby reducing weight.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If traditional light assembly construction is used, then lighting is provided, but manufacturing and assembly cost increase

Engineering Contradiction:

Improvemanufacturing and assembly costVSAvoidlighting function

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The window and light assembly are manufactured as a single integrated unit or pre-assembled together, reducing the number of assembly steps. This merging simplifies the manufacturing process and reduces labor costs while maintaining lighting reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The light emitting elements are pre-mounted on the window structure during window manufacturing, rather than being installed separately later. This preliminary action reduces assembly complexity and potential installation errors, lowering overall manufacturing costs.

Inventive Principle:

Principle #10Preliminary action

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 reduces the weight and complexity of vehicle lighting systems by integrating lights into the window glazing, offering aesthetic and utility functions while minimizing packaging space and manufacturing costs, achieving a weight reduction of greater than 10%-15% compared to non-integrated implementations.

Implementation Method 1

using multi-shot injection molding techniques to combine clear and colored thermoplastic polymers

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

at least one of the first vehicle window glazing component and the second vehicle window glazing component is translucent or transparent

Methodology Applied

Scientific EffectLight transmission:

Data Source

PatentUS12145498B2Illuminated graphic in an automotive plastic glazing

Publication Date: 2024.11.19 SABIC GLOBAL TECHNOLOGIES BV

AI summary

A plastic glazing of a window of a vehicle having a light feature includes a first vehicle window glazing component, a second vehicle window glazing component molded onto the first vehicle window glazing component, and a light unit configured to produce light for the light feature. The light unit being integrated with at least one of the following: the first vehicle window glazing component and the second vehicle window glazing component. The light unit further configured to direct the light for the light feature through or from at least one of the following: the first vehicle window glazing component and the second vehicle window glazing component. The plastic glazing is a one-piece molded plastic construction. At least one of the first vehicle window glazing component and the second vehicle window glazing component is translucent or transparent.