Headlight Reflector Pivoting via Intermediate Support Element
Solution Overview
Problem
Existing motor vehicle headlamp manufacturing techniques face challenges in precisely positioning the light source relative to the reflector due to complex molding requirements and high costs, often resulting in misalignment that affects the intensity of the light beam.
Innovation Solution
A motor vehicle headlamp design featuring an intermediate support element with positioning pins and bayonet mounting means that allows precise positioning of the reflector and light source within the housing, eliminating the need for complex molding and ensuring accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing is made in one piece by molding with projecting or recessed counterparts for the pivoting reflector, then the reflector can be pivotally mounted in the housing, but the molding process becomes complex and expensive requiring moving parts called wedges
Solution Approach 1:
The invention divides the housing into two separate components: the molded housing body and a distinct intermediate support element. This segmentation allows the housing to be molded with simple geometry while the support element provides the precise positioning features needed for the pivoting reflector mounting.
Solution Approach 2:
The intermediate support element acts as a mediator between the molded housing and the pivoting reflector. It provides the precise positioning counterparts and mounting features that would be difficult to achieve through molding alone, while still allowing the housing to be manufactured by simple molding processes.
2Ease of manufacture
If the lamp mounting hole and pivoting counterparts are produced by molding with the housing, then manufacturing is simplified, but the actual position of the lamp mounting hole relative to the pivoting counterparts is offset from the nominal position
Solution Approach 1:
The invention separates the positioning function from the housing molding process by introducing a distinct intermediate support element. This element carries the pivoting counterparts and positioning features, allowing the housing to be molded with simple geometry while achieving precise relative positioning through the support element's separate manufacturing process.
Solution Approach 2:
The intermediate support element serves as an intermediary that bridges the gap between the molded housing and the pivoting reflector assembly. It provides the precise positioning references needed to eliminate offsets between the lamp mounting hole and pivoting counterparts, while still allowing straightforward molding of the housing.
3Productivity
If the light source is positioned relative to the reflector using only molding features, then the manufacturing process is simplified, but the light source may not be precisely positioned at the focal point of the reflector, affecting beam intensity
Solution Approach 1:
The invention segments the positioning system into the molded housing and a separate intermediate support element that carries precise positioning features. This allows the housing to be manufactured efficiently by molding while the support element provides the precise geometric references needed to position the light source exactly at the reflector's focal point.
Solution Approach 2:
The intermediate support element acts as a mediator that ensures precise optical alignment between the light source and reflector. By carrying the pivoting counterparts and positioning features, it enables accurate positioning of the light source at the focal point, maximizing light beam intensity while still allowing efficient molded production of the housing.
Data Source
Figure 1~3
AI summary
The headlight has a case with a rear base, where the case houses a light source and a reflector. The source is mounted in a fixed manner in the case and the reflector is mounted in a pivoting manner around a transversal axis (B) with respect to the case. An intermediate support element made of metallic sheet is connected to the case in a fixed manner, and the reflector is mounted in a pivoting manner on the element.