Vehicle Interior Panel Surface Lighting Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing accent lighting for vehicle interior panels is often noticeable and pieced-together, especially on non-planar surfaces, due to the need for separate lighting modules and expensive conductive materials, leading to high costs and manufacturing defects.
Innovation Solution
A vehicle interior panel with an integrated substrate containing electrically active material molded into a plastic material, featuring a light-emitting film layer, an electrically conductive film layer, and a topcoat layer, which emits light from the panel's surface when a voltage potential is applied, eliminating the need for a separately applied conductive layer and providing a smooth, uninterrupted outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate lighting modules are installed in vehicle interior panels, then accent lighting function is achieved, but the panel has a pieced-together look and requires openings in the panel
Solution Approach 1:
The patent combines the lighting module components directly into the panel substrate by integrating the conductive material, light-emitting material, and dielectric material layers into the molded substrate itself. This merging eliminates separate lighting modules and creates a unified panel structure with built-in lighting capability, resolving the contradiction between integration and surface smoothness.
Solution Approach 2:
The substrate serves multiple functions simultaneously: it provides the structural base of the panel, contains the conductive material for electrical connection, holds the light-emitting material for illumination, and maintains the smooth outer surface. This multi-functionality allows the substrate to integrate lighting without requiring separate components or openings.
2Reliability
If expensive conductive materials with high metal content are used, then electrical conductivity is achieved, but manufacturing costs increase and scrap rate increases
Solution Approach 1:
The patent changes the parameters of the conductive material by using a sprayable conductive paint with reduced metal content compared to traditional high-metal-content conductive materials. This parameter change maintains sufficient electrical conductivity for the lighting application while reducing material cost and improving manufacturability by enabling more uniform application with lower scrap rates.
Solution Approach 2:
The patent employs a cost-effective conductive paint formulation that uses lower concentrations of expensive metal particles, replacing high-cost conductive materials with a more economical alternative that achieves the required electrical performance at reduced material and manufacturing costs.
3Reliability
If sprayable conductive paint with high metal content is used, then electrical conductivity is achieved, but uniform thick and defect-free paint films are difficult to achieve
Solution Approach 1:
The patent modifies the conductive paint formulation by reducing metal particle concentration and adjusting viscosity parameters to enable more uniform spray application. This parameter optimization allows for defect-free, consistent paint films while maintaining adequate electrical conductivity for the lighting function.
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 allows for integrated, cost-effective, and defect-free accent lighting that conforms to the shape of the panel, reducing manufacturing time and costs while providing a seamless, illuminated appearance on both planar and non-planar surfaces.
Implementation Method 1
The light-emitting film layer is configured to emit light when a voltage potential is applied across the first and second sides
Implementation Method 2
The electrically conductive film layer is at least partially transparent to the light emitted by the light-emitting film layer when the voltage potential is applied
Data Source
AI summary
A vehicle interior panel can be constructed to include accent lighting in the form of an electroluminescent element that includes a thin multi-layer film disposed over a substrate. The multi-layer film is sufficiently thin to conform to the shape of the substrate surface over which it is disposed, making it possible to integrate accent lighting with the panel in a manner that gives the impression that the light is produced at the visible outer surface of the panel. The substrate plays a dual role, providing both the overall shape, contour, and structure for the panel while additionally functioning as one of the electrodes of the electroluminescent element. The substrate includes an electrically active material that is integrated into a plastic material either by blending an additive with the plastic material prior to molding the substrate, or by insert molding and embedding electrically conductive material into the plastic material.