In-Surface Lens Assembly for Seamless Vehicle Panel Lighting
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Solution Overview
Problem
Existing automotive lighting units are complex, requiring numerous components and assembly steps, and often lack a seamless integration with vehicle panels, compromising protection and light transmission.
Innovation Solution
A seamless lighting arrangement for vehicle panels that integrates a lens with a bracket connection and a light unit, minimizing components and assembly steps, while ensuring protection and efficient light transmission through a sealed, flush-mounted design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lighting units are used with numerous components, then protection and light transmission can be achieved, but assembly complexity and number of assembly steps increase
Solution Approach 1:
The patent merges the lens and light unit into a single integrated assembly that connects to the panel as one unit. The lens includes an integrated seal that combines sealing, protection, and light transmission functions, eliminating the need for separate gaskets, mounting brackets, and alignment components that would otherwise be required.
Solution Approach 2:
The lens assembly serves multiple functions simultaneously: it seals the light unit to the panel, protects the light source from environmental factors, transmits light from the light unit to the exterior, and provides structural mounting support. This multi-functionality reduces the total number of components needed while maintaining reliability.
2Shape
If an in-surface sealing clear lens is integrated to a larger opaque panel, then a seamless appearance and protection are achieved, but the integration complexity increases
Solution Approach 1:
The seal is integrated directly into the lens structure rather than being a separate component. The lens includes a seal portion that forms a continuous sealing barrier between the light unit and panel, creating a seamless appearance while simplifying assembly to a single integration step.
Solution Approach 2:
The seal portion of the lens acts as a flexible sealing element that can conform to the panel opening and light unit interface. This integrated sealing film creates a flush, seamless appearance while being simple to install as part of the lens assembly.
3Reliability
If multiple components are assembled together, then protection and light transmission functions are achieved, but the number of assembly steps and time increase
Solution Approach 1:
The lens and light unit are pre-assembled into an integrated unit with the seal already in place. This single assembly connects to the panel in one operation, eliminating multiple separate assembly steps for mounting the light unit, installing the seal, and positioning the lens, thereby significantly increasing assembly productivity.
Solution Approach 2:
The seal and lens are pre-integrated into the lens assembly before installation to the panel. This preliminary assembly ensures proper sealing and alignment are already established, allowing for quick installation to the panel without requiring complex alignment or sealing operations during final assembly.
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
Reduces assembly complexity and ensures a seamless, protected light transmission by integrating a lens with a bracket connection, allowing for efficient light projection and alignment with vehicle panels.
Implementation Method 1
a lens with a bracket connection portion that connects to the bracket and a transmission portion positioned within the light aperture of the vehicle panel
Implementation Method 2
a bracket at a location near the light aperture... a lens with a bracket connection portion that connects to the bracket
Data Source
AI summary
A seamless lighting arrangement for a vehicle panel. The vehicle panel has an inside surface and an outside surface. The vehicle panel has a light aperture extending from the inside surface of the vehicle panel to the outside surface of the vehicle panel. Connected to the inside surface of the vehicle panel is a bracket. The seamless lighting arrangement further includes a lens with a bracket connection portion that connects to the bracket and a transmission portion positioned within the light aperture of the vehicle panel. The lens further includes a light unit fixedly connected to the lens. The light unit has a projector port for emitting light from a light source. The light transmission portion of the lens has a light input surface region formed on an inside surface of the lens and a light output surface region formed on an outside surface of the lens.