Hybrid Support Frame Structure for Thermally Stable Vehicle Lighting
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Solution Overview
Problem
Existing vehicle lighting device support frames made of thermoplastic materials suffer from high thermal expansion coefficients, leading to undesirable light impression shifts during temperature changes and remanent dimensional distortions. Additionally, alternative materials like thermosetting plastics and metallic die-cast components restrict design freedom and mechanical performance.
Innovation Solution
A support frame with a sandwich structure comprising at least two metallic sheet members in parallel arrangement and an intermediate plastic joint member, forming form-locking joints. This hybrid component combines low thermal distortion, high mechanical rigidity, and flexibility in component geometries, allowing for robust and dimensionally stable positioning of light modules relative to the vehicle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic materials are used for housings and module frames, then design freedom and ease of manufacture are improved, but thermal expansion causes dimensional instability and light impression shifts
Solution Approach 1:
The support frame is constructed as a composite structure combining metallic sheet members (aluminum or steel) with plastic joint members. The metallic sheets provide dimensional stability and low thermal expansion, while the plastic components enable flexible geometries and integrated mounting features. This composite approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The invention changes the material parameter from pure thermoplastic to a hybrid metal-plastic construction. By selecting metallic sheets with low thermal expansion coefficients and combining them with plastic joints, the overall thermal expansion behavior is optimized while maintaining manufacturing flexibility through the plastic components.
2Manufacturing precision
If thermosetting plastics or metallic die-cast components are used, then dimensional stability is improved, but design freedom and flexibility in component geometries are restricted
Solution Approach 1:
The hybrid construction allows the metallic sheets to provide dimensional stability similar to die-cast components, while the plastic joint members restore design freedom by enabling complex geometries and integrated features that are difficult to achieve with traditional die-casting or thermosetting plastics.
Solution Approach 2:
The support frame is divided into metallic sheet members and plastic joint members, each optimized for their specific function. The metallic segments provide structural stability, while the plastic segments provide geometric flexibility, allowing the overall structure to achieve both dimensional stability and design freedom.
3Strength
If a robust metallic support frame is used to replace cross members, then mechanical rigidity and structural integration are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The composite metal-plastic construction achieves the required mechanical rigidity through the metallic sheet members while the plastic joint members simplify the overall structure by integrating multiple functions (mounting, positioning, reinforcement) into single components, thereby reducing device complexity compared to traditional all-metallic robust structures.
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 support frame achieves a robust, dimensionally stable, and low-distortion positioning of light modules, ensuring high-resolution and high-precision lighting functionality. It can replace traditional cross members, providing structural integration and enhanced mechanical performance while maintaining design flexibility.
Implementation Method 1
The support frame features a sandwich structure of at least two metallic sheet members in parallel arrangement and at least one intermediate plastic joint member, which features form-locking joints with the sheet members
Data Source
AI summary
A support frame for components of a vehicle lighting device, especially for a housing or for a light module. The support frame features a sandwich structure of at least two metallic sheet members in parallel arrangement and at least one intermediate plastic joint member, which features form-locking joints with the sheet members.