Headlamp Reflector Spherical Joint Assembly Device
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Solution Overview
Problem
The assembly of spherical joints for vehicle headlamp reflectors is hindered by complex reflector shapes, leading to large device dimensions, high construction and assembly costs, and potential misalignment due to loose screws.
Innovation Solution
A space-saving assembly device featuring a tubular shank with elastically deformable fins and a pin that interferes with a cuttable diaphragm, allowing for secure and cost-effective assembly without screws, using a 'prisoner' mechanism to prevent loosening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate blocks are used for spherical joints with screws for fixation, then the assembly can be constructed, but the device dimensions become large and assembly costs increase
Solution Approach 1:
The invention merges the block and the fixation mechanism into a single integrated component. The block is provided with a recess that directly receives the spherical head, eliminating the need for separate fixation screws and reducing the overall assembly device dimensions while maintaining manufacturability.
Solution Approach 2:
The invention extracts the fixation function from a separate screw component and integrates it into the block structure itself through the recess design. This allows the spherical head to be retained without requiring additional fastening elements, thereby reducing assembly device volume.
2Ease of manufacture
If separate blocks with screws are used for spherical joints, then the joints can be assembled, but construction and assembly costs become high
Solution Approach 1:
The invention combines the block and fixation mechanism into one integrated component, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This integration simplifies the construction process and reduces assembly costs by eliminating separate screw components and their associated fastening operations.
Solution Approach 2:
The invention segments the fixation function into the recess structure of the block itself, allowing for simpler manufacturing processes. The recess is formed as an integral part of the block, eliminating the need for separate machining or assembly operations for fixation elements, thereby reducing construction and assembly costs.
3Reliability
If screws are used to secure blocks to the reflector, then the blocks can be fixed, but the screws can loosen in time causing misalignment
Solution Approach 1:
The invention removes the screw fixation mechanism entirely and replaces it with an integrated recess structure that retains the spherical head through geometric constraints. This eliminates the loosening problem inherent in threaded connections while maintaining secure fixation and preventing reflector misalignment over time.
Solution Approach 2:
The invention merges the fixation function into the block's recess structure, creating a permanent, non-loosening connection. The spherical head is retained within the recess through geometric interference and elastic deformation of the block material, providing stable, maintenance-free fixation that prevents reflector misalignment.
4Ease of operation
If the spherical head is introduced directly into the spherical seat, then the assembly is simple, but the screw must be uncovered or easily accessible which complicates the design
Solution Approach 1:
The invention removes the screw component entirely from the design, eliminating the need for accessibility considerations. The spherical head is introduced directly into the recess and retained through the elastic deformation of the block material, simplifying the assembly process and eliminating design complications related to screw access and fastening.
Solution Approach 2:
The invention combines the retention function into the recess structure itself, allowing the spherical head to be simply introduced and automatically retained through elastic deformation. This merging eliminates the need for separate fastening mechanisms and their associated accessibility requirements, maintaining assembly simplicity while securing the connection.
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 solution enables quick, reliable, and cost-effective assembly of spherical joints, preventing misalignment and loosening, thus improving the assembly process and reducing costs.
Implementation Method 1
the tubular shank is formed by at least one pair of fins, which are elastically deformable in a radial direction to the introduction axis
Implementation Method 2
a pin, that is shaped so as to be adapted for selectively taking a first position, in which the pin is aligned with the shank at a mouth thereof facing on the side of the spherical seat and is connected in one piece to the block through a cuttable diaphragm, and a second position in which the pin is at least partially driven into the tubular shank and interferes with the elastically deformable fins
Data Source
Figure 1~2
Figure 3a~3c
Figure 4
AI summary
A device (1) for assembling a spherical joint (2) for the reflector (3) of a headlamp comprising a tubular shank (14) obtained in one piece with a block (11) of the joint provided with a spherical seat (12) adapted to snappingly receive a spherical head (9) integrally in use to a headlamp body (5) by means of a respective stem (10), the shank (14) being formed by at least one pair of elastically deformable fins (16); a seat (15) for receiving the shank (14) obtained in one piece with the reflector (3); and a pin (17) adapted to selectively take a first position, being aligned with the shank (14) at a mouth (18) thereof facing the spherical seat and being connected in one piece to the block through a cuttable diaphragm (19), and a second position, in which it is at least partially driven within the tubular shank (14) and interferes with the elastically deformable fins (16) to such an extent that, when the shank is inserted in the reception seat, they interfere with a side wall (20) of the reception seat (15).