An ultra-thin surface light source structure and an automobile interior comprising the same
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Solution Overview
Problem
Traditional lighting components in automotive interiors are not integrated in areas with limited structural space, lacking translucent or glowing effects, and require separate circuit boards, light guides, and reflective films, leading to high costs and non-standardized designs.
Innovation Solution
An ultra-thin surface light source structure comprising a light guide substrate layer, circuit film, and reflective film, with pre-soldered LEDs and integrated optical patterns, produced through mould injection to form a one-piece, flexible, and standardized assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate components (circuit boards, light guides, reflective films) are used, then functional requirements are met, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent merges the circuit board, light guide, and reflective film into a single integrated component. The circuit traces are printed directly on the light guide substrate, and the reflective film is integrated into the same structure, eliminating the need for separate components and reducing assembly steps.
Solution Approach 2:
The light guide substrate serves multiple functions simultaneously: it acts as the structural base, the circuit board (with printed circuit traces), the light guide for diffusing light, and the reflective film (with printed reflective patterns). This multi-functionality reduces the total number of components needed.
2Productivity
If traditional separate components are used, then assembly is possible, but assembly process complexity increases and productivity decreases
Solution Approach 1:
By combining multiple components into one integrated part, the patent eliminates multiple assembly steps. The single-component design requires only placement into the housing cavity, dramatically simplifying the assembly process and improving productivity.
Solution Approach 2:
While the internal structure is integrated, the overall system maintains segmentation by keeping the light guide assembly as a separate replaceable unit that interfaces with the housing and LED module, allowing for modular assembly at higher levels.
3Adaptability or versatility
If light guides are customized for different applications, then optical requirements are met, but manufacturing cost increases
Solution Approach 1:
The patent achieves application-specific optimization through localized variations in the design of the integrated component, such as different circuit trace patterns, light guide thickness variations, or reflective film patterns, while maintaining the same basic manufacturing process and component structure.
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
Saves manufacturing costs, allows for flexible design and assembly, and achieves translucent or glowing effects with standardized moulds, reducing the need for separate components and assembly processes.
Implementation Method 1
A plurality of LED light sources are arranged at intervals in the light guide substrate layer
Implementation Method 2
the reflective film is printed on an upper part of the light guide substrate layer, and a plurality of reflective dots are arranged at intervals in the reflective film
Data Source
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AI summary
The present invention provides an ultra-thin surface light source structure and an automobile interior comprising the same. The ultra-thin surface light source structure comprises a light guide substrate layer, a circuit film and a reflective film. The circuit film is printed on bottom of the light guide substrate layer, and the reflective film is printed on an upper part of the light guide substrate layer. A plurality of LED light sources are arranged at intervals in the light guide substrate layer, and a plurality of reflective dots are arranged at intervals in the reflective film. The ultra-thin surface light source structure of the present invention has no separate LED circuit board parts, light guide parts, reflective brackets or reflective films, etc., which greatly saves manufacturing cost of components, assemblies and assembly production process. The ultra-thin surface light source is produced by mould injection to complete production of a standard surface light source, and can be cut according to a required shape. At the same time, a certain degree of bending is allowed, that is, using standardized products adapt to flexible designs and assembly requirements.