Reflection Suppression Device Louvre Array Manufacturing
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Solution Overview
Problem
Head-up displays in vehicles face glare issues due to reflective optical components that can direct sunlight into the driver's eye-box, causing discomfort and distraction, and existing manufacturing methods are complex and costly for producing effective reflection suppression devices.
Innovation Solution
A reflection suppression device comprising an array of elongated louvres angled to suppress glare from various angles, supported by a transparent structure with a serrated surface to enhance mechanical strength and redirect unwanted light, manufactured using a method that involves processing transparent and light-absorbing materials to form a serrated surface and louvre array, respectively, and integrating them for efficient mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If louvres are made thin and flexible to suppress glare effectively, then glare suppression performance is improved, but mechanical strength and rigidity deteriorate causing deformation under vibration
Solution Approach 1:
The patent combines light-absorbing material (for glare suppression) with transparent support structure material (for mechanical strength) to form a composite reflection suppression device. The support structure provides rigidity while the light-absorbing louvres provide glare suppression, resolving the contradiction between thin flexible louvres and mechanical strength.
Solution Approach 2:
The transparent support structure acts as an intermediary element that provides mechanical support to the thin louvres. It transfers and distributes mechanical loads, preventing deformation of the glare-suppressing louvres while maintaining their optical functionality.
2Object-affected harmful factors
If complex manufacturing methods are used to produce effective reflection suppression devices, then glare suppression performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the formation of the support structure and the attachment of louvres into a single injection moulding process. The support structure includes integrated attachment features (such as recesses or protrusions) that are formed during the same moulding cycle, eliminating separate assembly steps and reducing manufacturing complexity.
Solution Approach 2:
The injection moulding process serves multiple functions: it forms the transparent support structure, creates attachment features for the louvres, and can integrate the louvres themselves if made from the same or different materials. This multi-functional approach simplifies the manufacturing process while maintaining effective glare suppression.
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 effectively reduces glare without obstructing the primary function of the optical component, providing mechanical strength and rigidity while enabling efficient and cost-effective mass production of reflection suppression devices for head-up displays.
Implementation Method 1
additional unwanted light may advantageously be reflected away from an optical path of the optical component by the serrated surface
Implementation Method 2
Processing the light absorbing material comprises at least one selected from the group comprising: adjoining, gluing, painting or supporting the light absorbing material
Data Source
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AI summary
There is provided methods of manufacturing a reflection suppression device. The methods comprise a first step of forming a first component of the reflection suppression device by processing a transparent material to form a serrated surface Processing the transparent material comprises at least one selected from the group comprising extruding, injection moulding, hot embossing or cutting the transparent material. The methods further comprise a second step of forming a second component of the reflection suppression device by processing a light absorbing material to form a plurality of louvres arranged in an array. Processing the light absorbing material comprises at least one selected from the group comprising: adjoining, gluing, painting or supporting the light absorbing material in a support structure. At least one of the first and second steps comprises at least partially fixing the first component and second component together such that a periodicity of the serrated surface is equal to a periodicity of the array of louvres.