Vehicle Panel With Rear-Engraved 3D Pattern and Light Guide

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Solution Overview

Problem

Conventional vehicle interior lighting methods are limited to two-dimensional designs and suffer from high defect rates and poor mass-productivity due to laser processing, failing to provide a unique and luxurious three-dimensional lighting experience.

Innovation Solution

A vehicle panel with a three-dimensional pattern engraved on its rear surface, featuring a light guide plate, reflective sheet, and controlled coating, which emits a stereoscopic pattern when illuminated, using materials like polycarbonate and polymethyl methacrylate, and pigments to enhance light transmission and concealability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If laser processing is conducted on the surface to create lighting patterns, then design flexibility is improved, but manufacturing quality deteriorates due to surface steps and high defect rates

Engineering Contradiction:

Improvedesign flexibilityVSAvoidsurface quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Instead of applying laser processing to the front surface of the panel, the patent inverts the approach by forming the pattern on the rear surface through injection molding. The light guide plate transmits light from the rear patterned surface through the front surface, achieving design flexibility without surface damage or steps.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the mechanical laser processing system with an injection molding system. The pattern is formed mechanically during panel manufacturing by injecting material with the desired pattern embedded in the mold, eliminating the need for subsequent laser cutting and avoiding surface quality deterioration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If back coating and laser cutting are conducted to create lighting patterns, then design capability is improved, but productivity deteriorates due to high defect rates and rework requirements

Engineering Contradiction:

Improvedesign capabilityVSAvoidmass-productivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent performs the pattern formation action preliminarily during the injection molding process itself. The pattern is embedded in the mold cavity, so the panel is formed with the complete pattern already integrated, eliminating the need for subsequent coating and laser cutting operations that reduce productivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges multiple separate manufacturing operations (coating, laser cutting, pattern formation) into a single injection molding process. The pattern is created as an integral part of the panel during molding, combining what were previously sequential steps into one efficient operation that improves mass-productivity.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If conventional two-dimensional lighting patterns are used, then manufacturing simplicity is maintained, but aesthetic value deteriorates due to lack of three-dimensional effect

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidlighting dimensionality

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent transitions from two-dimensional surface patterns to three-dimensional patterns by forming raised and recessed features on the rear surface of the light guide plate during injection molding. Light passes through these three-dimensional features, creating depth and dimensionality in the emitted light pattern while maintaining manufacturing simplicity through the molding process.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

The solution enables the creation of high-quality, three-dimensional lighting patterns with controlled luminance and brightness, improving aesthetics and luxury feel, while reducing production costs and defects associated with conventional methods.

Implementation Method 1

a reflective sheet provided on an inner side of the light guide plate

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a light guide plate provided at a position corresponding to the panel body, a light source provided on a side of the light guide plate

Methodology Applied

Scientific EffectLight transmission: Light

Data Source

PatentUS11280951B2Vehicle panel for emitting stereoscopic pattern

Publication Date: 2022.03.22 HYUNDAI MOTOR CO LTD

AI summary

Disclosed is a panel for vehicles enabling a three-dimensional pattern to emit light including a panel body having a three-dimensional pattern portion having an engraved three-dimensional pattern on a rear surface thereof, a coating portion provided on an upper surface of the three-dimensional pattern portion, and a lighting portion disposed inside of the panel body configured to emit light to the panel body. The lighting portion includes a light guide plate provided at a position corresponding to the panel body, a light source provided on a side of the light guide plate, and a reflective sheet provided on an inner side of the light guide plate.