Submicrometric Metallic Coating for Automotive Lamp Appearance and Light Transmission
Solution Overview
Problem
Automotive lamp manufacturers face challenges in creating aesthetically pleasing and functional designs that meet legal requirements, as light rays need to pass through colored or designed substrates while maintaining appearance and functionality.
Innovation Solution
A method involving physical vapor deposition (PVD) to apply a submicrometric metallic coating on automotive lamp substrates, controlling process parameters like power level, gas flow rate, and deposition time to achieve desired light absorbance and appearance, allowing light to pass through when the light source is activated while appearing opaque when deactivated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a colored or designed coating is deposited onto the substrate, then the aesthetic appearance is improved, but the light transmission is reduced
Solution Approach 1:
The patent applies physical vapor deposition to create a metallic coating with submicrometric layer thickness, precisely controlling the deposition parameters (power level, gas flow rate, deposition time) to achieve a specific absorbance value. This parameter control allows the coating to provide desired aesthetic appearance while maintaining appropriate light transmission for automotive lamp functionality
Solution Approach 2:
The patent applies different absorbance values to different regions or functions of the same substrate. By controlling the coating process parameters, specific areas can have different light absorption characteristics, allowing different parts of the lamp to serve different aesthetic and functional purposes simultaneously
2Shape
If the coating layer thickness is increased to improve opacity and appearance, then the aesthetic appearance is improved, but the light transmission is excessively reduced
Solution Approach 1:
The patent precisely controls the coating thickness parameter within the submicrometric range (below 1 micrometer). By maintaining the thickness in this specific range and controlling other deposition parameters, the coating achieves sufficient opacity for aesthetic appearance while allowing adequate light transmission for lamp functionality
Solution Approach 2:
The patent applies a partial coating rather than a complete opaque layer. The submicrometric thickness provides just enough opacity for aesthetic purposes without fully blocking light transmission, achieving the desired balance between appearance and functionality
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 method enables the creation of automotive lamps with customizable colors and appearances that meet legal and aesthetic standards, ensuring functionality and appearance consistency while allowing light transmission when needed.
Implementation Method 1
sputter depositing a coating having a submicrometric layer thickness onto the substrate in a vacuum sputter deposition process
Implementation Method 2
enabling a glow discharge during the vacuum sputter deposition process
Data Source
AI summary
A coated substrate includes a substrate having a glow-discharged surface; and a coating having a submicrometric layer thickness sputter deposited onto the substrate. The coating having a submicrometric layer thickness has a predetermined absorbance. The predetermined absorbance regulates an amount of light transmitted from a light source through the substrate from a first side to a second side of the substrate. The substrate is opaque on the second side of the substrate when the light source is deactivated on the first side of the substrate. The predetermined absorbance varies as a function of one or more controlled process parameters.