Elastic Positioning Mechanism for Automotive Projection Optics
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Solution Overview
Problem
Existing logo light devices for projecting images in the automotive field face challenges due to manufacturing tolerances, which can result in either play or an overly tight press fit between housing and elements, leading to stress and potential breakage of glass image-forming elements.
Innovation Solution
The proposed device incorporates a housing with first and second stop elements and corresponding elastic positioning elements that exert spring forces in predefined directions to precisely position and hold the image-generating element and imaging optics, respectively, thereby compensating for manufacturing tolerances and reducing mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If crush ribs are used to press the image-forming element into the housing for precise positioning, then positioning precision is improved, but manufacturing tolerances cause either play or overly tight press fit leading to element breakage
Solution Approach 1:
The patent changes the mechanical parameter of the positioning system from rigid crush ribs to elastic positioning elements with spring force. This allows the system to adapt to manufacturing tolerances by exerting a controlled, compliant force that maintains positioning precision while preventing excessive compression that would break glass elements.
Solution Approach 2:
The invention introduces dynamic elasticity into the positioning system. The elastic positioning elements can dynamically adjust their compression force based on the actual fit between housing and element, transforming a static, forceful press-fit into a dynamic, adaptive positioning mechanism that protects fragile elements.
2Manufacturing precision
If elastic positioning elements exert force from multiple opposite sides to center elements, then positioning accuracy is improved, but bending or torsional forces are generated on the image-forming element
Solution Approach 1:
The patent applies local quality by positioning elastic elements at specific locations that exert force primarily in the compression direction rather than from all sides. This localized force application achieves positioning accuracy while avoiding the generation of bending or torsional moments on the image-forming element.
Solution Approach 2:
Instead of pressing the element from all sides toward a center point (traditional approach), the invention inverts the approach by allowing the element to be positioned and then securing it with elastic elements that exert unidirectional or limited-direction forces, eliminating the harmful multi-directional compression that causes stress.
3Productivity
If high-volume production is used to meet market demand, then productivity is improved, but coordinating components across multiple batches and mold cavities becomes very complex
Solution Approach 1:
The patent segments the positioning function into standardized elastic positioning elements that can be independently manufactured and then assembled. This modular approach allows high-volume production of individual components while simplifying the coordination of final assembly across multiple batches and mold cavities.
Solution Approach 2:
The elastic positioning elements serve multiple functions: they provide positioning, accommodate tolerances, and protect elements. This multi-functionality reduces the number of separate components and coordination steps needed in high-volume production, simplifying manufacturing across multiple batches and mold cavities.
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
This solution effectively reduces the influence of manufacturing tolerances on assembly, ensuring precise positioning of elements without exerting bending or torsional forces, thus minimizing the risk of breakage and enabling force-free mounting of image-forming elements.
Implementation Method 1
a first elastic positioning element, which is configured to exert a spring force on the image-generating element in order to press the image-generating element against the first stop element in a predefined direction
Implementation Method 2
a second elastic positioning element, which is configured to exert a spring force on the imaging optics in order to press the imaging optics against the second stop element in the predefined direction
Data Source
Figure 1
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Figure 4~5
AI summary
A device (100) for generating an image on a projection surface has at least one light source (104) designed to generate illumination light, an image-generating element (108) through which the illumination light can pass to generate the images, an imaging optics (110) designed to image the image-generating element (108) onto the projection surface to generate the images, and a housing (102a, 102b) designed to accommodate at least the image-generating element (108) and the imaging optics (110). The housing (102a, 102b) has a first stop element (202) and a first elastic positioning element (200) designed to exert a spring force on the image-generating element (108) in order to press the image-generating element (108) against the first stop element (202) in a predefined direction (P1).Alternatively or additionally, the housing (102a, 102b) comprises a second stop element (602) and a second elastic positioning element (600) which is designed to exert a spring force on the imaging optics (110) in order to press the imaging optics (110) in the predefined direction (P3) against the second stop element.