Vehicle Lighting Lens Plasma Coating for Thin Functional Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The industrial production of closing glasses for vehicle lighting devices with advanced properties such as anti-fog, anti-abrasion, and electromagnetic wave management is complex and results in a thick varnish that degrades the product design, failing to meet customer expectations.
Innovation Solution
A closing glass structure comprising a first transparent polymer layer with a second and third transparent layer produced by atmospheric plasma treatment, where the second layer is formed using a plasma torch and the third layer is polymerized using volume dielectric barrier discharge, allowing for optimized deposition on large surfaces and enhanced properties like anti-fog and anti-scratch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional deposition methods are used to create functional layers on closing glass, then advanced properties (anti-fog, anti-abrasion, electromagnetic wave management) are achieved, but the layer thickness becomes significant and degrades product design
Solution Approach 1:
The patent replaces conventional mechanical/chemical deposition methods with plasma-based deposition. The plasma process allows for functional layers to be deposited as ultra-thin films (nanometer scale) compared to conventional methods, achieving the same protective and functional properties without significant thickness buildup that would degrade design aesthetics.
Solution Approach 2:
The patent changes the deposition parameters by using plasma temperature and energy control to achieve precise thin-film deposition. By controlling plasma parameters (power, pressure, gas flow), the process deposits functional layers at the nanometer scale rather than micrometer scale, resolving the contradiction between functional reliability and design aesthetics.
2Area of stationary object
If conventional deposition methods are used on large surfaces, then complete coverage is achieved, but the process complexity and industrial production difficulty increase
Solution Approach 1:
The plasma deposition device is designed with multi-functionality to handle various closing glass sizes and shapes. The same plasma source and chamber configuration can deposit uniform thin films across small or large surfaces by adjusting plasma power and scan speed, eliminating the need for complex equipment variations and simplifying industrial production.
Solution Approach 2:
The patent employs dynamic plasma deposition where the plasma source can move relative to the closing glass surface or the glass can be moved through the plasma field. This dynamic approach ensures uniform deposition across large surfaces while maintaining process simplicity and ease of industrial implementation.
3Reliability
If multiple functional layers are deposited to provide comprehensive properties, then reliability and performance are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges multiple functional layer depositions into a single integrated plasma process. Different functional materials can be deposited in sequence or simultaneously using the same plasma chamber and equipment, providing comprehensive functional performance (anti-fog, anti-abrasion, electromagnetic shielding) without requiring separate complex manufacturing lines for each layer.
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 production of closing glasses with high electromagnetic radiation transmission (>87%) and additional properties like anti-corrosion, hydrophilic, or hydrophobic characteristics, reducing degradation and improving design aesthetics while being cost-effective and efficient.
Implementation Method 1
the treatment of at least one of the second transparent layer and/or third transparent layer being assisted by atmospheric plasma with a plasma torch
Implementation Method 2
the third transparent layer being polymerized using volume dielectric barrier discharge
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a closing lens (4) of a lighting device (2) for a vehicle (1) comprising at least a first transparent layer (6) of a polymer material, characterized in that the closing lens (4) comprises at least a second transparent layer (8) and a third transparent layer (10) formed by processing at least one precursor component (CP), the layers being made in overlapping of each other, the processing of at least one of the second transparent layer (8) and/or third transparent layer (10) being assisted by atmospheric plasma with a plasma torch.