Transparent Roof Panel Light In-Coupling with Molded Optical Adhesive
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Solution Overview
Problem
Existing transparent roof panel assemblies for vehicles face challenges in precisely shaping the light in-coupling element and efficiently minimizing the use of expensive optical adhesive, while maintaining high transparency and adaptability to the panel's contour.
Innovation Solution
The use of a mould, preferably made of transparent plastic, is applied on the light entering side of the in-coupling element during moulding, allowing for precise shaping and minimizing adhesive usage, with options for deformable sections to accommodate thermal expansion and adaptable attachment methods using adhesive tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mould is used to shape the in-coupling element, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a flexible mould that can be deformed to match the contour of the panel's interior side. This flexible mould maintains manufacturing precision for the light entering side while avoiding the need for complex rigid mould structures, thereby resolving the contradiction between precision and complexity.
Solution Approach 2:
The mould acts as an intermediary element between the optical adhesive and the panel interior side. It transfers the desired shape to the adhesive during curing, enabling precise shaping without requiring complex direct attachment mechanisms, thus improving precision while keeping the overall device complexity manageable.
2Loss of substance
If optical adhesive is minimized for cost reasons, then loss of substance is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent applies optical adhesive only in the necessary amount to fill the space between the mould and the panel interior side, rather than using excessive adhesive. The mould confines the adhesive to the precise area needed, minimizing material usage while ensuring complete coverage and precise shaping, thus resolving the contradiction between reducing substance loss and maintaining manufacturing precision.
3Illumination intensity
If the mould is made transparent for light transmission, then illumination intensity is improved, but strength deteriorates
Solution Approach 1:
The patent employs a transparent mould material that combines optical clarity with sufficient mechanical strength. By selecting appropriate transparent materials and optimizing the mould design, both light transmission and structural integrity are maintained, resolving the contradiction between illumination intensity and strength.
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 approach enables efficient light transmission, precise light shaping, and cost-effective use of optical adhesive, ensuring optimal transparency and adaptability to the vehicle roof panel's contour.
Implementation Method 1
an in-coupling element to in-couple light into the panel from the interior side of the panel, the in-coupling element being attached to the interior side of the panel and redirecting light from the at least one light source into the panel
Implementation Method 2
redirecting light from the at least one light source into the panel
Implementation Method 3
The clear plastic strip forming the mould may be provided with deformable sections along the length of the strip to compensate for thermal expansions during use of the roof panel assembly
Data Source
Figure 1~2
Figure 3a~3c
Figure 4a~4c
AI summary
A transparent roof panel assembly for a vehicle roof comprises a transparent panel (3) and at least one light source (8) arranged to provide light in the panel. An in-coupling element (9) to in-couple light into the panel from the interior side of the panel, is attached to the interior side of the panel and redirects light from the at least one light source (8) into the panel. The in-coupling element (9) is made at least partly from optical adhesive which is directly moulded to the interior side of the panel. The in-coupling element is bounded at least on its light entering side by a mould (11) for the optical adhesive at least during moulding of the in-coupling element.