Vehicle Headlight LED Housing Interlocking Mounting
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Solution Overview
Problem
Existing vehicle headlight designs face challenges in simplified assembly and precise alignment of light-emitting diode chips with respect to reflectors, particularly due to the complexity of fastening mechanisms and potential shading of light by fastening components.
Innovation Solution
The use of projections or recesses on the housing of the lighting unit that interlock with matching counterparts on the reflector, combined with precise bore designs, allows for exact alignment and secure mounting without rotational movement, enabling a screw connection that minimizes light shading and accommodates various electrical connection types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bayonet lock or press-fit pin fastening mechanism is used, then the lighting unit can be securely mounted on the headlight, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The fastening mechanism is segmented into separate functional elements: a clamp arm that can be independently actuated, a pivot axis for rotational movement, and a release lever for disengagement. This segmentation allows the assembly to be simplified while maintaining secure mounting capability.
Solution Approach 2:
The clamp arm is designed to be spring-loaded, automatically engaging with the reflector when the lighting unit is inserted. The spring force provides self-latching functionality without requiring additional fastening steps, making the assembly process self-service and simplifying the overall mechanism.
2Reliability
If complex fastening components are used to secure the lighting unit, then reliable mounting is achieved, but light shading occurs due to the fastening components blocking the light path
Solution Approach 1:
The fastening function is extracted from the main body of the lighting unit and implemented through a separate clamp arm that engages with the reflector. This extraction allows the fastening components to be positioned away from the light path, eliminating light shading while maintaining reliable mounting security.
Solution Approach 2:
The clamp arm acts as an intermediary element between the lighting unit housing and the reflector. It provides the necessary mechanical connection and adjustment capability without interfering with the optical path, as it is positioned laterally rather than in the light beam direction.
3Reliability
If traditional fastening mechanisms are used, then secure mounting is achieved, but precise alignment of the light-emitting diode chip and primary optics with the reflector optical axis becomes difficult
Solution Approach 1:
The clamp arm is designed with rotational freedom around a pivot axis, allowing dynamic adjustment during assembly. This dynamic capability enables precise alignment of the lighting unit with the reflector optical axis by permitting small angular adjustments while maintaining secure mounting, thereby improving manufacturing precision.
Data Source
AI summary
The invention relates to an illumination unit, preferably for vehicle headlights, comprising at least one light emitting diode chip (3) and a housing (100) which at least partially surrounds the at least one light emitting diode chip (3). The housing (100) is equipped with fastening means for mounting the illumination unit in a vehicle headlight. The fastening means encompass at least one protrusion or a recess (121, 122) which is disposed on the housing (100). In order to mount the illumination unit in the lamp, the at least one protrusion or recess (121, 122) cooperates with a matching counterpart (210) on a lamp piece (200) of the lamp in such a way that the at least one protrusion or the at least one recess (122) and the counterpart (210) matchingly engage into one another.