Vehicle Headlamp Bracket Alignment via Compressible Spacer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current vehicle headlamp designs face challenges in achieving precise optical alignment and ease of assembly, as they can be complex and costly, and adjustments may loosen over time due to environmental influences like temperature fluctuations and vibrations.
Innovation Solution
A vehicle headlamp design featuring a holding bracket and spacer elements with adjustable connector devices, where the spacer elements have a lower modulus of elasticity than the holding bracket and support, allowing for easy alignment and secure fixation using an activatable adhesive embedded in microcapsules, ensuring long-term stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the holding bracket is rigidly fixed to the support, then the alignment stability is improved, but the ease of assembly and adjustment deteriorates
Solution Approach 1:
The connector device transitions from a loose state during assembly to a fixed state during operation. The holding bracket can be freely positioned during assembly but becomes securely fixed after the connector device is tightened, resolving the contradiction between ease of assembly and alignment stability.
Solution Approach 2:
The connection system is divided into separate components: the holding bracket, the connector device, and the support. This segmentation allows the holding bracket to be independently positioned during assembly and then securely fixed by the connector device, achieving both ease of assembly and stability.
2Ease of operation
If the connector device is made adjustable, then the ease of operation is improved, but the reliability deteriorates due to loosening over time
Solution Approach 1:
The connector device is pre-configured with threading and engagement features that automatically prevent loosening once tightened. The preliminary design of the connection mechanism ensures that the adjustable connector device maintains its position reliably over time without requiring frequent readjustment.
3Manufacturing precision
If the spacer element height is reduced to align components, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The spacer element is pre-formed with the precise height required for alignment. This preliminary preparation of the spacer element with the correct dimensions eliminates the need for complex adjustment procedures during assembly, achieving both alignment precision and assembly simplicity.
4Ease of manufacture
If the modulus of elasticity of the spacer element is reduced, then the ease of manufacture is improved, but the stability deteriorates
Solution Approach 1:
The spacer element is designed to be compressible during assembly to facilitate alignment, but once compressed and locked by the connector device, it maintains its position stably. The dynamic behavior of the spacer element transitions from flexible during assembly to stable during operation, resolving the contradiction between ease of manufacture and stability.
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 design enables easy and precise assembly and adjustment of light sources and ancillary optical units, maintaining alignment despite environmental factors, reducing the need for frequent re-adjustments and enhancing durability.
Implementation Method 1
the at least one spacer element can be pressed together with the aid of the at least one connector device by the holding bracket and the support, wherein the height of the at least one spacer element is reduced
Implementation Method 2
ensuring long-term stability against environmental factors
Implementation Method 3
using an activatable adhesive embedded in microcapsules
Data Source
AI summary
The invention relates to a vehicle headlamp (1) comprising a light source (2) and an add-on optical unit (3), wherein the light source (2) is fastened on a carrier (10), in which bores (12, 3) are provided in order to each receive a connection means (20, 21). A spacer element (30, 31) is arranged on the carrier (10). A holding bracket (40) is arranged on the spacer element (30, 31). The connection means (20, 21) is intended to connect the holding bracket (40) to the carrier (10) and is for this purpose inserted into a corresponding opening (41, 42) and into the corresponding bore (12, 13). In a first position of the holding bracket (40), in which the connection means (20, 21) is inserted into the opening (41, 42), but is not fixed, the holding bracket (40) can be moved relative to the connection means (20, 21) within the opening (41, 42) in a plane normal to an axis (22, 23) in order to allow the add-on optical unit (3) to be oriented relative to the light source (2) in the plane. The spacer element (30, 31) can be pressed together with the aid of the connection means (20, 21) by the holding bracket (40) and the carrier (10), wherein the height (35, 36) of one spacer element (30, 31) is reduced and a fixed, second position of the holding bracket (40) is achieved.