Polymer Vehicle Window with Integrated LED Assembly
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Solution Overview
Problem
Vehicle windows made of glass are inflexible and difficult to integrate with electronic components, limiting their shape variability and functionality, especially when incorporating lighting features.
Innovation Solution
A polymer vehicle window composed of an inner opaque polymeric layer with recesses for an LED arrangement, connected to a circuit board and power source, and an outer transparent polymeric layer for emission, produced via two-component injection molding, providing a lightweight, flexible, and aesthetically appealing solution with integrated lighting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass is used for vehicle windows, then optical transparency and durability are improved, but shape flexibility and ease of integration with electronic components deteriorate
Solution Approach 1:
The patent changes the material parameter from glass to polymer, which fundamentally alters the physical properties to achieve both durability and shape flexibility. The polymer material maintains optical transparency while enabling complex geometries and integration with LED components that glass cannot accommodate.
Solution Approach 2:
The patent uses composite material structures with multiple polymer layers (transparent and opaque) to achieve the desired properties. The composite construction allows the window to maintain durability while enabling shape flexibility and electronic component integration through the polymer's inherent characteristics.
2Reliability
If glass is used for vehicle windows, then optical transparency is improved, but integration with electronic components and shape variability deteriorate
Solution Approach 1:
The patent changes the material from glass to polymer, which enables direct integration with electronic components like LEDs. The polymer's flexibility and formability allow electronic components to be embedded within the window structure itself, rather than being separate attachments as with glass windows.
Solution Approach 2:
The patent merges the window structure with electronic components by integrating LEDs directly into the polymer window body. The recesses and cavities formed in the polymer allow electronic components to be incorporated into the window itself, creating a unified structure rather than separate elements.
3Weight of moving object
If polymer materials are used to replace glass, then weight is reduced and shape flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single injection molding process. The window body, recesses, and mounting features for electronic components are all formed in one step, reducing overall manufacturing complexity despite the multi-layer composite structure.
Solution Approach 2:
The patent incorporates mounting features, recesses, and structural elements directly into the molded polymer part during manufacturing. This preliminary formation of all necessary features eliminates subsequent assembly steps and reduces manufacturing complexity.
4Reliability
If multiple polymer layers are used to achieve desired properties, then optical transparency and durability are improved, but manufacturing process complexity increases
Solution Approach 1:
The patent merges multiple polymer layers into a single integrated component through co-injection molding. The transparent and opaque layers are formed simultaneously in one manufacturing process, eliminating the need for separate assembly steps and reducing overall process complexity.
Solution Approach 2:
The patent uses composite material technology to combine multiple polymer layers with different properties (transparent, opaque, flexible) into a single integrated structure. The co-injection molding process creates a durable multi-layer composite while simplifying manufacturing by forming all layers in one operation.
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 polymer window offers shape versatility, reduced weight, enhanced durability, and effective integration of lighting features, achieving a glass-like appearance with improved mechanical and aesthetic properties while reducing manufacturing energy and costs.
Implementation Method 1
produced via two-component injection molding
Implementation Method 2
An LED arrangement with at least one LED or also OLED... The light emitted by the LEDs can thus be emitted directly to the outside through the outer transparent polymeric layer
Data Source
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AI summary
The invention relates to a polymeric vehicle window, at least comprising: a) a composite component (8) comprising an inner opaque polymeric layer (1) and an outer transparent polymeric layer (2), wherein the inner opaque polymeric layer (1) and the outer transparent polymeric layer (2) are connected in a planar manner, b) the inner opaque polymeric layer (1), which has at least one at least partially piercing hole (3), an LED assembly (4), at least comprising an LED (5), a printed circuit board (PCB) (6), and electrical contacting (7), being arranged in the hole (3), and c) the LED assembly (4) is placed in such a way that the LED (5) is placed in the direction of the outer transparent assembly (4).