Automotive lighting and / or signaling device with external decorative elements and related assembly method
The described method securely attaches decorative elements to motor vehicle lighting devices using a welding pin and spacer, combined with a filling element, addressing adhesive degradation and water intrusion issues, ensuring a stable and cost-effective solution.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- MARELLI AUTOMOTIVE LIGHTING ITAL SPA
- Filing Date
- 2026-02-18
- Publication Date
- 2026-05-11
AI Technical Summary
Conventional methods for attaching decorative elements to motor vehicle lighting and signaling devices face issues such as adhesive degradation due to atmospheric exposure and vibration, leading to gaps and water intrusion, and welding solutions are costly and prone to separation.
A method involving a welding process with a welding pin and spacer element to secure a decorative element to a lens body, combined with a liquid-impermeable filling element to prevent water ingress and maintain a stable bond, using laser or ultrasonic welding.
Ensures a durable, cost-effective attachment of decorative elements without the need for additional sealing, preventing water stagnation and damage from thermal stress, while maintaining aesthetic integrity.
Smart Images
Figure 2026076351000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a motor vehicle lighting and / or signaling device comprising an external decorative element and a related assembly method.
Background Art
[0002] The term motor vehicle lighting and / or signaling device is used herein in a very broad sense and includes rear or front motor vehicle lighting, the latter also being named headlight or headlamp.
[0003] As is known, motor vehicle lighting is a device intended to provide at least one lighting and / or signaling function of a vehicle, such as, for example, a position lamp, a turn signal, a brake lamp, a rear fog lamp, a reversing lamp, a dipped beam headlamp, a main beam headlamp, etc.
[0004] Furthermore, it is understood that the term also includes ceiling lights, dashboards or parts thereof, and thus motor vehicle lighting and / or signaling devices are installed inside or outside the vehicle.
[0005] As is known, the motor vehicle lighting and / or signaling device substantially houses at least one light source inside and comprises a hollow container body closed by an external lens body.
[0006] Preferably, a light source of the LED type is combined with, for example, at least one light guide that receives the light rays created by the light source and transmits the light rays towards the lens body by means of total internal reflection (TIR) conventionally.
[0007] For aesthetic reasons, the lighting and / or signaling device comprises a decorative element on the outside of the container body. Such decorative elements often comprise chrome-plated parts
[0008] Decorating the lighting and / or signaling device with the use of such external decorative elements involves a series of technical difficulties to be overcome.
[0009] To associate light with an external decorative element, a truly stable and lasting bond is achieved between the outer surface of the lens body and the inner wall of the decorative element associated with it.
[0010] Such a bond is achieved by adhesive or welding.
[0011] However, solutions that provide adhesion have the drawback of adhesive degradation, as the direct action of atmospheric substances and the continuous vibration and thermal stress that lighting and / or signaling devices experience during their operation cause them to lose their physicochemical properties and yield.
[0012] To overcome the latter technical challenge, it is known to protect the periphery of the bonded portion by proper surrounding sealing. However, the use of such gaskets inevitably involves a further increase in the cost of the components used, the overall cost of the lighting and / or signaling device, and the assembly process of the lighting itself.
[0013] Therefore, in recent automotive lighting and / or signaling devices, it is preferred to join decorative elements to the lens body by a welding process, such as ultrasonic or laser welding. However, the shape or excessive size of the welded joint can lead to the formation of a gap between the decorative element and the lens body at the end of the welding process. Such gaps are sites of soil and especially water intrusion, and in the case of ice, expansion can cause separation of the decorative element.
[0014] For all these reasons, conventional welding solutions have undeniable drawbacks. [Overview of the project]
[0015] Therefore, there is a need to make available automotive lighting and / or signaling devices that have decorative elements capable of solving the technical problems mentioned in the prior art with reference to the prior art.
[0016] Such requirements are met by the automotive lighting and / or signaling device described in claim 1 and by the method for assembling the automotive lighting and / or signaling device described in claim 13.
[0017] Other embodiments of the present invention are described in the dependent claims.
[0018] Further features and advantages of the present invention will become more apparent from the following description of preferred non-limiting embodiments thereof. [Brief explanation of the drawing]
[0019] [Figure 1] The assembled configuration and schematic perspective views from different angles of a lighting and / or signaling device according to embodiments of the present invention are shown. [Figure 2] The assembled configuration and schematic perspective views from different angles of a lighting and / or signaling device according to an embodiment of the present invention are shown. [Figure 3] Figure 1-2 shows a schematic perspective view of the separated components of the lighting and / or signaling device. [Figure 4] Figure 1 shows a front view of detail IV. [Figure 5] Figure 4 shows a cross-sectional view of the lighting and / or signaling device, cut along the cross-section VV of Figure 4. [Figure 6] A cross-sectional view of a subsequent step for assembling a lighting and / or signaling device according to the present invention by welding is shown. [Figure 7] A cross-sectional view of a subsequent step for assembling a lighting and / or signaling device according to the present invention by welding is shown. [Figure 8] A cross-sectional view of a subsequent step for assembling a lighting and / or signaling device according to the present invention by welding is shown. [Figure 9] Three schematic perspective views from different angles of decorative details of a lighting and / or signaling device according to the present invention are shown. [Modes for carrying out the invention]
[0020] Elements or parts of elements that are common among the described embodiments will hereinafter be denoted using the same reference numerals.
[0021] Referring to the foregoing figures, reference numeral 4 denotes, by way of example, a lighting and / or signaling device such as automotive lighting, and will hereinafter be referred to without loss of generality for this reason.
[0022] As described above, the expression "lighting and / or signaling device" means, for example, a position lamp such as a front position lamp, a tail lamp, a side marker, a turn signal, a brake lamp, a rear fog lamp, a main beam headlamp, a dipped beam headlamp, etc., or automotive rear lighting or automotive front lighting having at least one light on the outside of the vehicle having a lighting and / or signaling function, the latter also being known as a headlight or headlamp.
[0023] Furthermore, the term lighting and / or signaling device also means an interior ceiling light, a dashboard or part thereof, a display device.
[0024] Thus, as will be described in more detail hereinafter, in its signaling function, the device is capable of transmitting not only optical signals, logos but also any kind of text and optical messages.
[0025] The lighting and / or signaling device 4 comprises a container body or housing 8, usually made of a polymeric material such as acrylonitrile butadiene styrene or ABS, and the lighting and / or signaling device 4 can usually be fixed to each vehicle or any type of support of the vehicle.
[0026] For the purposes of the present invention, the container body or housing 8 has any shape, size or position. For example, the container body 8 is also not directly connected to the bodywork of the associated vehicle or other external fixture.
[0027] As can be observed, the container body 8 can also be fixed inside the car, for example, on the dashboard or rear shelf.
[0028] The container body 8 separates the containment housing 12 that houses multiple components of the lighting and / or signaling device.
[0029] In particular, the confinement housing 12 houses a plurality of light sources 16, including, for example, LEDs, OLEDs, and lasers, which are arranged and supported within the confinement housing 12.
[0030] For example, the lens body 20 is installed so as to close the container body 8 at least partially, closing the containment housing 12 which houses at least one light source 16.
[0031] For the purposes of the present invention, the lens body 20 is located outside the lighting and / or signaling device 4 so as to define at least one outer wall of the lighting and / or signaling device that is directly exposed to the atmosphere.
[0032] According to possible embodiments, the material of the lens body 20 is a polymer, i.e., a resin such as PMMA (polymethyl methacrylate) or PC (polycarbonate). Thus, the material of the lens body is at least partially transparent, semi-transparent, or translucent, and also comprises one or more opaque portions.
[0033] Therefore, the lens body 20 is configured to be at least partially traversed by the light rays produced by the light source 16 and transmitted to the outside of the confinement housing 12, as better described below.
[0034] According to possible embodiments, at least one optical guide 24, made of a transparent polymer material such as PC or PMMA, is also housed inside the confinement housing 12. A light source 16 housed in the confinement housing 12 is intended to precisely supply, for example, such at least one optical guide 24. Thus, the optical guide is configured to accept, at least partially, a ray produced by the at least one light source 16 as input, transmit the ray by internal total internal reflection, and send the ray out of the confinement base 12 through the lens body 20 as output.
[0035] The lighting and / or signaling device 4 further comprises at least one decorative element 28 that is, for example, opaque to the light rays emitted by at least one light source 16 and applied to the outer wall 32 of the lens body 20 opposite the confinement base 12. In other words, the outer wall 32 is outward from the lighting and / or signaling device 4 and faces directly to an external observer.
[0036] Preferably, the decorative element 28 has a chrome-plated portion on its outer surface 38 opposite to the inner wall 36.
[0037] Clearly, various alternatives are possible to achieve the decorative function of the outer surface 38 of the decorative element 28.
[0038] Preferably, the inner wall 36 of the decorative element 28 that directly faces the outer wall 32 of the lens body 20 is provided with at least one welding pin 40 that creates a welding point with the lens body 20.
[0039] In other words, the welding pin 40 creates mechanical fastening of the decorative element 28 to the outer wall 32 of the lens body 20, as better described below.
[0040] Preferably, the welding pin 40 is made of an opaque material.
[0041] The inner wall 36 of the decorative element 28 further includes at least one spacer element 44 that determines the minimum distance 48 and volume or gap 52 between the outer wall 32 of the lens body 20 and the inner wall 36 of the decorative element 28.
[0042] In other words, the spacer element 44 defines the minimum distance or gap 48 between the decorative element 28 and the lens body 20. Obviously, such a minimum distance or gap 48 is measured locally along a line perpendicular to the respective planes tangent to the outer wall 32 of the lens body 20 and the inner wall 36 of the decorative element 28.
[0043] The presence of such a minimum gap 28 also defines an open volume 52 separated between the outer wall 32 of the lens body 20 and the inner wall 36 of the decorative element 28.
[0044] Such minimum spacing 48 is preferably on the order of 0.1-3 mm.
[0045] Preferably, the inner wall 36 of the decorative element 28 further comprises at least one transport element 56 that is advantageous for the outflow of liquid and / or soil entering the volume 52 through the minimum gap 48.
[0046] According to a possible embodiment, the transport element 56 has the form of fins that are inclined to facilitate the outflow of liquid downward. Obviously, the form of the transport element 56 must be installed according to its position, assuming that the transport element is for final use, i.e., when the lighting and / or signaling device is applied to a vehicle associated with a position planned for the device. In other words, when the lighting and / or signaling device is mounted on the vehicle, the transport element 56 is positioned so as to be substantially perpendicular to the ground, or so as to have such an inclination (e.g., slanting) to carry all the liquid toward the ground in any case.
[0047] Preferably, the transport element 56 has a thickness greater than or equal to the minimum spacing 48. Obviously, the minimum spacing 48 changes along the extension of the lens body 20 and the decorative element 28. Therefore, preferably, the transport element 56 has a thickness greater than or equal to the minimum spacing 48 that occurs near the transport element 56 itself.
[0048] According to a possible embodiment, at least one liquid-impermeable filling element 60 configured to at least partially fill the volume or gap 52 is associated with the inner wall 36 of the decorative element.
[0049] Preferably, the filling element 60 is an elastically compressible element within the volume or gap 52.
[0050] For example, the filling element 60 is an EPDM sponge.
[0051] Preferably, the filling element 60 is a sponge element having closed cells that prevent it from retaining liquid and / or soil. In other words, the filling element 60 is made of a water-repellent material.
[0052] According to the embodiment, the filling element 60 is at least partially compressed inside the volume or gap 52.
[0053] Preferably, the decorative element 28 comprises a plurality of transport elements 56 arranged at intervals from each other by the filling element 60.
[0054] This creates a preferential outflow pathway for all liquids and / or soil, preventing the liquids and soil from stagnating in the volume or void 52.
[0055] According to the embodiment, the transport element 56 and the spacer element 44 are identical to each other. In other words, the same element serves both the function of transporting liquid / soil and as a spacer between the lens body 20 and the decorative element 28.
[0056] During operation, the liquid / soil accumulated in the gap 52 moves away from the filling element 60 towards the transport element 56, i.e., the spacer element 44. Here, the liquid / soil is collected by the transport element 56, i.e., the spacer element 44, and then slides towards the ground, thus keeping the gap 52 clean.
[0057] A method for assembling a lighting and / or signaling device according to the present invention will be described therefrom.
[0058] In particular, the method comprises the steps of providing a decorative element 28 and a lens body 20, and associating the decorative element 28 with the lens body 20, and bringing at least one welding pin 40 of the decorative element 28 into contact with the outer wall 32 of the lens body 20.
[0059] In the initial step (Figure 6), the welding pin 40 protrudes more than the protrusion of the spacer element 44. In other words, when the welding pin 40 is brought to contact the outer wall 32 of the lens body 20, the spacer element does not come into contact with the outer wall 32 of the lens body 20 itself.
[0060] The process can then be advanced by performing welding, at least partially melting the welding pins 40 until the spacer element 44 and the outer wall 32 of the lens body 20 come into contact (Figure 7-8).
[0061] This ensures that the spacer element 44 maintains the correct relative positioning (minimum distance) between the decorative element 28 and the lens body 20.
[0062] Preferably, the welding is a laser welding procedure performed by directing a laser beam from the inside 64 of a lens body 20, which acts as a transparent element to the laser beam, so that the laser beam is directed to the welding pin 40, which acts as a laser beam absorbing element made of an opaque material. Thereafter, overheating and therefore softening and welding occur at the boundary between the lens body 20 and the welding pin 40.
[0063] According to a further possible embodiment, the welding is ultrasonic welding, and the welding pin 40 is made of a transparent material.
[0064] When it is intended to create a decorative element having a chrome plate on its outer surface 38, the chrome treatment can be carried out before welding is performed on the lens body 20.
[0065] In such a step of chroming the outer surface 38 of the decorative element 28 opposite the inner wall 36, it is necessary to avoid coating the welding pins 40 with chromium.
[0066] As can be understood from the above description, the present invention can overcome the drawbacks shown in the background art.
[0067] In particular, the automotive lighting and / or signaling device according to the present invention enables the association of decorative elements in an economical, stable, and permanent manner.
[0068] The automotive lighting and / or signaling device according to the present invention does not provide a sealing insulator for a decorative element associated with a lens body, but rather provides a gap between the decorative element and the lens body so that a liquid, such as water, can pass through and simultaneously drain away.
[0069] In particular, the transport elements are arranged and configured to favor such downward flow of the liquid.
[0070] The presence of the filling element simultaneously reduces the amount of liquid flowing in, guiding the liquid towards the transport element, which in turn facilitates its discharge from the volume between the decorative element and the lens body.
[0071] As a result, the water does not stagnate in any way, and there is no risk of damage to the welding points or the elements of the automotive lighting and / or signaling device itself due to expansion during the transition to a solid state, for example.
[0072] Those skilled in the art can make numerous changes and modifications to the above-described lighting and / or signaling device and assembly method, all of which fall within the scope of the present invention as defined by the following claims, satisfying specific accompanying requirements.
Claims
1. - A container body (8) that separates the enclosed housing (12) closed by the lens body (20), - The confinement housing (12) houses at least one light source (16) configured to emit a ray that at least partially crosses the lens body (20) so as to transmit the ray to the outside of the confinement housing (12), - comprising at least one decorative element (28) applied to the outer wall (32) of the lens body (20) opposite to the enclosing housing (12), A lighting and / or signaling device for a vehicle, wherein the inner wall (36) of the decorative element (28) directly facing the outer wall (32) of the lens body (20) comprises at least one welding pin (40) that creates a welding point with the lens body (20), at least one spacer element (44) that determines the minimum distance (48) and volume or gap (52) between the outer wall (32) of the lens body (20) and the inner wall (36) of the decorative element (28), and at least one transport element (56) that is favorable for the outflow of liquid entering the volume (52) through the distance (48).
2. The lighting and / or signaling device (4) according to claim 1, wherein the transport element (56) has the form of a fin that is inclined to facilitate the outflow of the liquid downward.
3. The lighting and / or signaling device (4) according to claim 1 or 2, wherein the transport element (56) has a thickness greater than or equal to the spacing (48).
4. The lighting and / or signaling device (4) according to any one of claims 1 to 3, wherein at least one filling element (60) that is impermeable to liquid and configured to at least partially fill the volume (52) is associated with the inner wall (36).
5. The lighting and / or signaling device (4) according to claim 4, wherein the filling element (60) is an elastically compressible element inside the volume (52).
6. The lighting and / or signaling device (4) according to claim 4 or 5, wherein the filling element (60) is an EPDM sponge.
7. The lighting and / or signaling device (4) according to any one of claims 4 to 6, wherein the filling element (60) is a sponge-like element having closed cells.
8. The filling element (60) is at least partially compressed inside the volume (52), as described in any one of claims 4 to 7, for the lighting and / or signaling device (4).
9. The lighting and / or signaling device (4) according to any one of claims 4 to 8, comprising a plurality of transport elements (56) arranged at intervals from one another by the filling element (60).
10. The lighting and / or signaling device (4) according to any one of claims 1 to 9, wherein the transport element (56) and the spacer element (44) are the same as each other.
11. The welding pin (40) is made of a material that is opaque to the welding laser, according to any one of claims 1 to 10, the illumination and / or signaling device (4).
12. The decorative element (28) on the outer surface (38) opposite to the inner wall (36) comprises a chrome-plated portion, according to any one of claims 1 to 11, the lighting and / or signaling device (4).
13. The lighting and / or signaling device (4) according to any one of claims 1 to 12, wherein at least one of the decorative elements (28) is opaque to the light rays.
14. The steps of providing a lighting and / or signaling device (4) according to any one of claims 1 to 13, The steps include associating the decorative element (28) with the lens body (20) and bringing at least one of the welding pins (40) to contact the outer surface (32) of the lens body (20), A method for assembling a lighting and / or signaling device (4), comprising the step of performing welding to melt the welding pin (40) until contact is reached between the spacer element (44) and the outer surface (32) of the lens body (20).
15. The assembly method according to claim 14, wherein the welding is ultrasonic welding or laser welding performed by directing a laser beam from the inside (64) of the lens body (20), which functions as a penetrating element, to a welding pin (40), which functions as an absorbing element.
16. The assembly method according to claim 14 or 15, comprising the step of chroming the outer surface (38) of the decorative element (28) opposite to the inner wall (36), thereby avoiding coating the welding pin (40) with chromium.