Co-extruded Light Pipe with Resilient Wings for Uniform Step Rail Illumination
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Solution Overview
Problem
Multi-lamp illumination devices for vehicle step rails often produce non-uniform light patterns and are expensive and difficult to install due to their complex arrangement of individual lamps and wire harnesses, with issues exacerbated by lamp malfunctions.
Innovation Solution
A single extruded illumination device with an elongated light pipe made of optically transmissive material and resilient attachment wings, designed to securely fit within a containment channel, reducing the number of parts and assembly complexity through co-extrusion and snap-in installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple individual lamps and wire harnesses are used to provide illumination, then the illumination device can provide ground lighting, but the light pattern becomes non-uniform with bright and dark spots
Solution Approach 1:
The illumination device is segmented into multiple individual LED lamps arranged in a specific pattern, with each lamp providing localized illumination. This segmentation allows the light to be distributed across multiple points, creating a more uniform overall light pattern while maintaining the ability to provide adequate ground illumination.
Solution Approach 2:
Each individual lamp in the array provides localized illumination with specific intensity and directionality. By optimizing the local quality of each lamp's light output and strategically positioning them, the collective effect produces a uniform illumination pattern across the ground area.
2Illumination intensity
If multiple individual lamps with wire harnesses are used, then ground illumination can be provided, but installation and connection become expensive and difficult
Solution Approach 1:
Multiple individual LED lamps are merged into a single integrated illumination assembly with a common mounting structure and simplified electrical connections. This merging reduces the number of separate components that need to be installed and connected, thereby simplifying installation procedures and reducing manufacturing costs while maintaining the ground illumination function.
Solution Approach 2:
The illumination device is designed as a universal assembly that can be installed in various locations and configurations. The integrated design with standardized mounting features and electrical connections makes it easy to manufacture and install in different applications, reducing both manufacturing complexity and installation difficulty.
3Illumination intensity
If multiple individual lamps are used, then ground illumination can be provided, but the device becomes expensive and difficult to install
Solution Approach 1:
The illumination device combines multiple individual LED lamps, mounting brackets, and electrical connections into a single integrated assembly. This merging reduces the total number of separate components that need to be handled during installation, thereby reducing device complexity while maintaining the ground illumination capability.
4Illumination intensity
If lamps are individually mounted in sockets, then ground illumination can be provided, but the light pattern becomes non-uniform when lamps malfunction
Solution Approach 1:
The illumination system is segmented into multiple independent LED lamps within an integrated assembly, where each lamp contributes to the overall uniform light pattern. This segmentation provides redundancy, so that if one lamp malfunctions, the other lamps continue to provide illumination, maintaining light pattern consistency and reliability.
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 provides a uniform light distribution, enhances durability, and simplifies installation by eliminating the need for additional mounting hardware or adhesives, while maintaining the device securely in place.
Implementation Method 1
an elongated light pipe made of an optically transmissive material and having a reflecting side that reflects light within the light pipe
Implementation Method 2
having a reflecting side that reflects light within the light pipe
Implementation Method 3
a first attachment wing made of a resilient material... the first and second attachment wings resiliently snap into the containment channel and securely maintain the illumination device in place
Data Source
AI summary
An illumination device that includes an elongated light pipe and attachment wings integrally formed on the sides of the light pipe so that the illumination device can be easily, yet securely, installed within a containment channel, such as those found on the underside of a vehicle step rail. The elongated light pipe is made of an optically transmissive material, the attachment wings are made of a different resilient material, and the overall device is a single extruded component that has a co-extrusion boundary separating the two materials. The illumination device illuminates the ground, for example, when passengers are entering or exiting the vehicle.