Polycarbonate LED Covers with Deep Gloss Day/Night Design
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Solution Overview
Problem
Conventional methods for producing LED lighting elements with a day/night design require complex processes involving multiple components, leading to inefficiencies and rejects due to the need for precise insertion of films, which complicates the production of components with deep gloss and illumination effects.
Innovation Solution
A translucent moulding compound comprising at least 90% aromatic polycarbonate, combined with specific colourants, carbon black, and scattering additives, allowing for a single material to achieve a deep gloss look and significant appearance change under LED illumination, simplifying the production process and eliminating the need for bonding multiple components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional methods using multiple components (hardcoat film insert-moulded with transparent layers) are used to achieve deep gloss effect, then the deep gloss appearance is improved, but the device complexity and manufacturing precision requirements increase significantly
Solution Approach 1:
The patent combines multiple functions (deep gloss effect, translucency, and structural integrity) into a single polycarbonate composition rather than using separate hardcoat film and transparent layer components. This merging eliminates the need for complex insert-moulding processes and reduces the number of parts while achieving the desired deep gloss appearance.
Solution Approach 2:
The polycarbonate composition serves multiple functions simultaneously: it provides the deep gloss appearance, maintains translucency for LED light transmission, and acts as the structural housing material. This multi-functionality eliminates the need for separate specialized components like hardcoat films.
2Shape
If hardcoat film insert-moulding process is used to achieve deep gloss, then the deep gloss effect is improved, but the manufacturing precision and productivity decrease due to precise insertion requirements
Solution Approach 1:
The deep gloss effect is achieved through the bulk properties of the polycarbonate composition itself rather than through a separate hardcoat film layer. This eliminates the need for precise film insertion and positioning during the moulding process, significantly reducing manufacturing precision requirements.
Solution Approach 2:
The patent extracts the deep gloss property from the separate hardcoat film component and integrates it directly into the polycarbonate material composition. This eliminates the need for the complex insert-moulding process and associated precision requirements.
3Adaptability or versatility
If multiple components are bonded together to achieve day/night design, then the functional requirements are met, but the device complexity increases
Solution Approach 1:
The patent merges the day/night design functionality into a single material system where the polycarbonate composition's optical properties (translucency and deep gloss) enable the housing to appear dark in unilluminated state and bright/colored when LED light shines through, eliminating the need for separate decorative elements.
Solution Approach 2:
The polycarbonate housing material simultaneously provides structural support, deep gloss appearance, and day/night design functionality through its optical properties. This universal material replaces multiple specialized components needed for achieving the same functional effects.
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 production of LED lighting units with a deep gloss effect in a single material, achieving a distinct appearance under illumination, particularly with RGB-LED light, while maintaining a dark appearance in the unilluminated state, thus simplifying the production process and reducing rejects.
Implementation Method 1
The moulding has been produced from a translucent moulding compound based on aromatic polycarbonate... which combines specific colourants with carbon black and a scattering additive
Implementation Method 2
0.00001% by weight to 0.05% by weight of carbon black... in order to achieve a deep gloss effect
Data Source
AI summary
The present invention relates to LED lighting elements comprising translucent mouldings composed of polycarbonate-based moulding compounds, comprising a colourant mixture, carbon black, scattering additive and optionally white pigment, as used, for example, as covers with a day/night design. Through combination with one or more RGB-LEDs, it is possible to achieve surprising colour effects in night design with presence of a deep gloss effect in mouldings that are black and grey in day design.