Vehicle Switch Film-Printing Method for Visibility
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Solution Overview
Problem
Conventional manufacturing processes for emergency light switches in vehicles involve multiple painting and drying steps, increasing production time and costs, and result in reduced visibility due to light passing through the symbol-printed areas, especially at night.
Innovation Solution
A switch structure and manufacturing method using a film-printing method to create a single-part switch with a light-transmissive part and a film-printing layer on the knob, allowing light to pass through while preventing leakage, and integrating the moving block and knob using a single mold for improved visibility and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple painting processes (red painting, black painting, high-gloss painting) are used to manufacture the emergency light switch, then the visibility and appearance of the switch is improved, but the manufacturing time and production cost increase
Solution Approach 1:
The patent combines multiple painting processes (red painting, black painting, and high-gloss painting) into a single injection molding process by integrating color masterbatches into the resin material. This merging of processes eliminates sequential painting steps and drying time, directly reducing manufacturing time while maintaining visibility through the light-transmissive white base material with red symbol injection
Solution Approach 2:
The patent applies preliminary action by pre-mixing color masterbatches (red and black) into the resin material before injection molding. This preliminary color integration eliminates the need for subsequent painting processes, as the colors are already embedded in the material structure, thereby reducing manufacturing steps and time while preserving the visibility function
2Illumination intensity
If multiple painting processes are used to create the red and black symbol areas, then the symbol visibility is improved, but the number of manufacturing steps and complexity increase
Solution Approach 1:
The patent merges multiple painting operations into a single injection molding operation by using color masterbatches embedded in the resin. The red symbol area and black text area are both created in one molding step, eliminating the complexity of sequential painting processes while maintaining clear symbol visibility through the light-transmissive material
Solution Approach 2:
The patent changes the manufacturing parameter from surface-level painting to bulk material coloration by injecting resin with integrated color masterbatches. This parameter change simplifies the manufacturing process by eliminating multiple painting steps and drying cycles, while the light-transmissive property of the white resin maintains symbol visibility
3Reliability
If chrome plating is used on the switch surface, then the durability and appearance are improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent extracts the chrome plating process from the manufacturing sequence by replacing it with injection-molded surface finishes. The high-gloss appearance previously achieved through chrome plating is now obtained directly through the injection molding process using glossy resin materials, eliminating the plating step and associated time while maintaining durability through the molded surface structure
Data Source
AI summary
A switch structure includes a light-emitting part configured to receive power from a vehicle and to radiate light, a moving block located so as to surround the light-emitting part, a light-transmissive part configured to allow light radiated from the light-emitting part to pass through an opening in the moving block, and a film-printing layer located on a top surface of the light-transmissive part and including a symbol.