Vehicular Headlamp Bracket Structure for Low-Weight Rigidity
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Solution Overview
Problem
There is a demand for a vehicle lamp that achieves weight reduction while maintaining rigidity, particularly in the bracket attachment portion, without causing stress concentration and requiring additional reinforcing ribs.
Innovation Solution
The vehicle lamp incorporates a lamp body with a cylindrical boss and a bracket that has a Y-shaped vertical cross-section or a semi-cylindrical shape, along with a vent hole design, to enhance rigidity and reduce weight by integrating a curved surface as a reinforcing rib, eliminating the need for additional ribs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rib is added to the bracket to increase rigidity, then the rigidity of the bracket is improved, but the weight of the lamp body increases
Solution Approach 1:
The patent integrates the reinforcing rib directly into the bracket structure, making them a single integrated component rather than separate parts. This merging eliminates the need for additional fastening elements and reduces overall weight while maintaining the rigidity-enhancing function of the rib structure
Solution Approach 2:
The patent employs curved surfaces and arch-like structures in the bracket design, particularly in the connection portions between the bracket and lamp body. These curved geometries provide structural reinforcement through geometric strength, improving rigidity without requiring additional material or weight
2Weight of moving object
If the bracket is thinned to reduce weight, then the weight of the lamp body is reduced, but the strength of the bracket decreases
Solution Approach 1:
The patent applies varying thickness distributions within the bracket structure, with thinner sections in non-critical areas and strategically thicker sections at connection points and load-bearing regions. This localized quality optimization reduces overall weight while maintaining necessary strength where required
Solution Approach 2:
The curved and arched geometries in the thin bracket design provide structural reinforcement through shape alone, allowing the bracket to maintain sufficient strength despite reduced thickness. The curved connection portions create natural stress distribution patterns that prevent stress concentration
Data Source
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AI summary
Provided is a vehicular headlamp (1) comprising a container-shaped lamp body (2) provided with a front opening (2'), and a front cover (4) assembled with the front opening (2') of the lamp body (2) and defining a light chamber (S) on the inner side. On a constituting surface (69) that constitutes the lamp body (2), a cylindrical element (7) is provided protruding. The constituting surface (69) protrudes from at least part of the area on the axially extending outer-peripheral lateral surface of the cylindrical element (7). The constituting surface (69) is curved extending towards the base end or the tip end of the cylindrical element (7), with the constituting surface (69) and the cylindrical element (7) being made unitary. The increased curved surface makes it possible to improve rigidity and reduce thickness.