Elastic Optical Element Attachment for Vehicle Light Module Assembly

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Solution Overview

Problem

Existing light modules for motor vehicles are complex and difficult to assemble and adjust, particularly in ensuring accurate positioning and orientation of optical elements to comply with photometric standards, which can lead to assembly errors and increased risk of dazzling other road users.

Innovation Solution

A light module design featuring elastic attachment means and positioning elements that facilitate easy assembly and adjustment, including a support structure for light sources and optical elements with microlenses, allowing for precise alignment and secure attachment, thereby simplifying the assembly process and reducing the risk of misalignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional attachment methods are used for optical elements, then secure attachment is achieved, but assembly complexity and difficulty increase

Engineering Contradiction:

Improvesecure attachmentVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The attachment system is segmented into separate positioning means and elastic attachment means, allowing independent optimization of each function while simplifying overall assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The elastic attachment means automatically secures the optical element when positioned correctly, eliminating the need for additional fastening operations or complex adjustment procedures

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If traditional positioning methods are used for optical elements, then positioning accuracy can be achieved, but assembly time and difficulty increase

Engineering Contradiction:

Improvepositioning accuracyVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Positioning means are pre-configured on the support structure, enabling automatic alignment and positioning of the optical element during a single assembly operation without requiring subsequent adjustments

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Complex mechanical positioning and adjustment mechanisms are replaced with integrated positioning means that provide accurate alignment through simplified geometric constraints

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple separate components are used for attachment, then secure fixation is achieved, but the number of assembly steps increases

Engineering Contradiction:

Improvefixation securityVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Positioning and attachment functions are merged into an integrated system where positioning means and elastic attachment means work together in a single assembly operation, eliminating multiple separate steps

Inventive Principle:

Principle #5Merging (Combining)

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 design enhances the ease of assembly and adjustment of light modules, ensuring accurate positioning and reduced risk of dazzling, while also allowing for selective activation of light segments, making it suitable for adaptive driving beam functions.

Implementation Method 1

elastic attachment means for attaching said optical element in the predefined position on the support

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11221120B2Light module and lighting device for a motor vehicle comprising such a light module

Publication Date: 2022.01.11 VALEO VISION SA

AI summary

A light module includes at least one light source, a light source support, and an optical element suitable for receiving rays emitted by the light source. The optical element includes structure for positioning the optical element in a predefined position on the support and an elastic attachment device for attaching the optical element in the predefined position on the support.