Headlamp Plastic Cover Lens Diagonal Locking Strip
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Solution Overview
Problem
Existing assemblies for strips on plastic cover lenses for headlamps face challenges in easy replacement and mechanical tension issues, as they often rely on casting compounds or screws, which complicate removal and can lead to wear.
Innovation Solution
The design features locking means extending diagonally from the plastic cover lens surface, engaging with receivers on a backing strip, utilizing a form-locking mechanism with snapping means to secure the strip without high mechanical tension, allowing for easy replacement and minimizing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a casting compound is used to attach the strip to the plastic cover lens, then permanent and precise positioning is achieved, but the strip becomes difficult to replace and requires hardening time during mounting
Solution Approach 1:
The attachment system is segmented into separate components: a locking profile with locking arms on the plastic cover lens, and corresponding locking recesses on the strip. This segmentation allows the strip to be attached and detached without chemical bonding, enabling easy replacement while maintaining secure positioning during use.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (casting compound) with a mechanical locking system consisting of locking arms that engage with locking recesses. This mechanical substitution eliminates the need for hardening time and enables tool-free replacement of the strip while maintaining reliable attachment.
2Reliability
If screws are used to attach the strip to the plastic cover lens, then the strip can be securely attached, but the screw sockets are subjected to mechanical tension and may prematurely wear when cleaning agents are applied
Solution Approach 1:
The locking profile is integrated as a thin, flexible element within the plastic cover lens structure, allowing it to absorb mechanical stresses without concentrating tension on specific socket points. The distributed locking arms engage with multiple locking recesses along the strip, distributing mechanical loads and reducing wear on individual attachment points during cleaning and maintenance operations.
3Device complexity
If locking means extend perpendicular to the surface of the plastic cover lens, then the structure is simple, but high mechanical tension is generated in the locking means when the strip is attached
Solution Approach 1:
The locking arms are designed with asymmetric geometry, extending diagonally at approximately 45 degrees from the surface rather than perpendicular to it. This asymmetric orientation allows the locking arms to engage with locking recesses in a way that distributes mechanical tension more evenly, reducing peak stresses while maintaining structural simplicity. The diagonal extension creates a more favorable stress distribution pattern during attachment and operation.
Data Source
AI summary
An assembly comprising a strip on the exterior of a plastic cover lens for a headlamp. Locking means are formed on the exterior of the plastic cover lens, which extend diagonally, in a transverse direction, from the surface of the plastic cover lens, and that the strip is designed as a backing strip and exhibits locking means receivers in which the locking means engage. At least one snapping means is provided on the backing strip and one complementary snapping means is provided on the plastic cover lens in order to secure the backing strip in the transverse direction (Y).