Automotive Lamp Ball Socket Pivot Vibration Damping
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Solution Overview
Problem
Automotive lamps are prone to mechanical vibrations due to weak coupling with the vehicle body, especially with LED-based lighting modules which are heavier and more susceptible to temperature-related performance degradation, leading to potential dazzling of oncoming drivers.
Innovation Solution
A ball socket with a pivot mechanism that restricts movement to a single axis, using low friction materials and integrated pivoting elements to reduce vibrations and facilitate controlled aiming of the optical block, while being cost-effectively manufactured with injection molding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED-based lighting modules are used, then illumination intensity and energy efficiency are improved, but weight increases leading to larger mechanical vibrations
Solution Approach 1:
The lighting module is divided into separate functional components: the optical block containing LEDs and the heatsink for thermal management are integrated, while the ball socket with pivot mechanism provides independent mechanical support and vibration damping. This segmentation allows the heavy LED module to be properly supported without compromising illumination performance.
Solution Approach 2:
The patent changes the mechanical parameters of the mounting system by introducing a ball socket with pivot mechanism that allows controlled movement and damping. This parameter change in the mechanical coupling system enables the heavy LED module to be supported while reducing vibrations, resolving the contradiction between weight and vibration control.
2Stability of the object's composition
If the optical block is securely coupled to the vehicle body, then mechanical vibrations are reduced, but aiming adjustment becomes difficult
Solution Approach 1:
The ball socket with pivot mechanism introduces controlled dynamics to the otherwise static mounting system. The pivot allows rotational movement for aiming adjustment while the ball socket provides stable support. This dynamic element enables both secure coupling and easy aiming adjustment by allowing controlled rotation around the pivot axis.
Solution Approach 2:
The ball socket acts as an intermediary between the optical block and the vehicle body. It provides stable mechanical support while the pivot within the ball socket enables aiming adjustments. This intermediary component resolves the contradiction by decoupling the stability function from the adjustment function.
3Ease of operation
If a pivot is added to the bracket to enable aiming adjustment, then ease of operation is improved, but manufacturing precision and friction increase leading to higher aiming torques
Solution Approach 1:
The pivot mechanism is merged with the ball socket structure rather than being a separate component. This integration simplifies manufacturing by combining multiple functions (support, rotation, damping) into a single component, reducing the need for high-precision manufacturing of separate pivot elements and their interfaces.
Solution Approach 2:
The ball socket with pivot mechanism is designed to self-adjust and self-dampen vibrations through its inherent mechanical properties. The pivot provides natural rotation capability without requiring additional lubrication or precision maintenance, and the ball socket structure itself provides vibration damping, reducing the need for high manufacturing precision.
4Ease of manufacture
If the pivot surfaces are made rough for better manufacturing, then ease of manufacture is improved, but friction increases leading to higher aiming torques
Solution Approach 1:
The patent changes the surface parameter of the pivot from rough to smooth/polished. This parameter change reduces friction between pivot surfaces, thereby reducing aiming torques. The slight increase in manufacturing complexity is justified by the significant reduction in operational torque requirements.
Solution Approach 2:
The ball socket and pivot are made from composite materials or materials with specific friction-reducing properties. This material selection allows for easier manufacturing while maintaining low friction surfaces, resolving the contradiction between ease of manufacture and aiming torque.
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 effectively reduces mechanical vibrations and allows for precise vertical aiming of the optical block, enhancing stability and reducing the risk of dazzling other drivers, while being suitable for heavier LED-based modules and reducing manufacturing complexity and volume.
Implementation Method 1
Owing to the pivot, the optical block may be rotated, however, due to limitations in the manufacturing of the pivot (the surfaces thereof are rough and do not feature a polished material), there is a high friction between the components resulting in aiming torques that are beyond acceptable levels
Implementation Method 2
the pivot comprises a low friction material. In this sense, the coefficient of friction of the material becomes smaller than or equal to 0,40, and more preferably a coefficient of friction smaller than or equal to 0,30 and/or 0,20
Implementation Method 3
The vibration damper provides a counter-oscillation (by means of a mass and a spring-elastic connection) that counteracts the vibrations of the headlamp
Implementation Method 4
The vibration damper provides a counter-oscillation (by means of a mass and a spring-elastic connection) that counteracts the vibrations of the headlamp
Data Source
Figure 1A~1B
Figure 2~3
Figure 4A~4B
AI summary
A ball socket (100) for fixing and aiming an optical block of an automotive lamp, the ball socket (100) comprising: a first portion (110) comprising a cavity (111) adapted to receive an element (501) for rotation of the ball socket (100); a second portion (120) adapted to mate to a component (200) for supporting the optical block; and a pivot adapted to provide the ball socket (100) with a pivoting axis (150). Also, a method for producing an assembly (300) for fixing and aiming an optical block of an automotive lamp, and a method for manufacturing a pivotal ball socket (100).