Optical Block Housing Coupling Lugs with Protrusions
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Solution Overview
Problem
Current optical unit housings secured to protective glass using flat, smooth coupling ribs face challenges in achieving optimal positioning due to manufacturing tolerances, requiring iterative mold modifications and multiple mold productions during the development phase.
Innovation Solution
The housing features coupling lugs with side protuberances and protrusions, allowing for improved alignment with the vibration tool, minimizing positioning clearances and ensuring optimal positioning during the vibration phase, which includes varying orientations and shapes such as prisms with triangular bases and increasing heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flat, smooth coupling ribs are used, then the housing can be manufactured with simple molds, but optimal positioning of the housing relative to the protective glass cannot be guaranteed due to manufacturing tolerances
Solution Approach 1:
The coupling lugs are designed with localized geometric features (protrusions and side faces) that create specific engagement points with the vibration tool. This local geometric differentiation enables precise positioning without requiring complex overall lug structures, resolving the contradiction between positioning precision and structural simplicity.
Solution Approach 2:
The coupling lugs feature asymmetric geometries with protrusions on specific side faces rather than uniform symmetric designs. This asymmetry creates directional engagement with the tool, minimizing positioning clearances in critical directions while maintaining manufacturability, thus improving positioning precision without excessive complexity.
2Productivity
If flat, smooth coupling ribs are used, then the coupling structure remains simple, but iterative mold modifications and multiple mold productions are required during development phase
Solution Approach 1:
The coupling lugs are designed with predetermined geometric features (protrusions and specific side face orientations) that pre-establish optimal positioning characteristics. This preliminary design eliminates the need for iterative mold modifications during development, as the positioning capability is built-in from the start, thereby improving development efficiency while maintaining reasonable structural complexity.
3Measurement precision
If coupling lugs with protrusions are used, then positioning clearances are minimized and optimal positioning is guaranteed, but the coupling lug structure becomes more complex
Solution Approach 1:
Rather than making the entire coupling lug complex, only specific local regions are given protruding geometric features. This localized complexity achieves the positioning accuracy goal while keeping the overall lug structure relatively simple and manufacturable.
Solution Approach 2:
The protrusions extend the coupling lugs in lateral dimensions beyond the basic rib structure. This dimensional extension creates additional engagement surfaces with the tool, improving positioning accuracy through enhanced geometric constraints without requiring excessive complexity in the primary lug body.
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
This design facilitates precise positioning and secure attachment of the housing to the protective glass, reducing development time and mold production needs by minimizing clearances and ensuring accurate alignment during the securing phase.
Implementation Method 1
This welding results from the melting, by friction induced by the vibrations, of welding teeth which are initially present on the rear peripheral edge of the protective glass.
Implementation Method 2
Once the coupling has been made, the tool vibrates the casing so that its front peripheral edge is joined by welding to the rear peripheral edge of the protective glass.
Implementation Method 3
This welding results from the melting, by friction induced by the vibrations, of welding teeth which are initially present on the rear peripheral edge of the protective glass.
Data Source
Figure 1~2
Figure 3~4
AI summary
A housing (BB), suitable for forming part of a vehicle's optical unit (BO), comprises a front peripheral edge opposite a rear face (FR) equipped with at least two protruding coupling tabs (PC1-PC4). Each coupling tab (PC1-PC4) comprises a long, slender main part (PP) extending on at least one lateral face (FL1-FL2) by at least one lateral protrusion (PL) to define a male shape suitable for fitting into an internal housing having a female shape homologous to this male shape and defined in a corresponding part of a tool intended to vibrate the housing (BB) to permanently attach its front peripheral edge (BP) to a rear peripheral edge of a protective lens during a vibration bonding phase.