Vehicle Door Lamp Unit Structure to Prevent LED Rattling
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Solution Overview
Problem
The existing lamp units for vehicle doors experience rattling of the light-emitting elements due to their coupling with busbars, leading to potential damage and instability.
Innovation Solution
A lamp unit design featuring a holder member with a base board and a retaining member that sandwiches the light-emitting element, along with a cover member to create a housing chamber, preventing rattling and damage by securing the base board and retaining member within a recessed housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the light-emitting element is coupled to the busbar, then the light-emitting element can be electrically connected, but the light-emitting element may rattle relative to the holder member
Solution Approach 1:
The patent introduces a base board that separates the electrical connection function (busbar coupling) from the mechanical support function (holder member attachment). The light-emitting element is mounted on the base board, which is then attached to the holder member, creating distinct functional segments that prevent rattling while maintaining electrical connectivity.
Solution Approach 2:
The base board acts as an intermediary component between the busbar and the holder member. It provides a stable mounting surface for the light-emitting element and distributes mechanical stresses, preventing direct transmission of vibrations that would cause rattling while maintaining the electrical connection pathway.
2Strength
If the retaining member is made solid to secure the base board, then the base board is firmly retained, but the weight of the retaining member increases
Solution Approach 1:
The retaining member incorporates light passing holes (apertures) that reduce its overall weight while maintaining structural integrity. These holes allow light transmission and reduce material usage, achieving weight reduction without compromising the retaining member's ability to securely hold the base board through its outer frame and beam structure.
Data Source
AI summary
To provide a lamp unit in which rattling of a light-emitting element is prevented, a lamp unit includes: a holder member attached to an attachment object, a base board provided with a light-emitting element coupled on a main surface thereof; a retaining member that engages the holder member to sandwich the base board between the retaining member and the holder member such that the base board is retained at a prescribed position on the holder member; and a cover member that is at least partially light-transmissive and is attached to the holder member such that the cover member cooperates with the holder member to define a housing chamber for housing the base board and the retaining member.