Integrated Light Guide Lens for Compact Automotive Lighting
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Solution Overview
Problem
Existing light devices for motor vehicles require significant packaging space due to the need for separate molded interior light guides and exterior lenses, which is not feasible in applications with narrow packaging constraints like side repeaters and side mounter turn signals.
Innovation Solution
A lighting device that integrates the light guide and outer lens into a single item, eliminating the need for a separate exterior lens and reducing packaging space by combining the lens thicknesses, thereby minimizing the overall thickness from 8-18 mm to 4-10 mm or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate molded interior light guides and exterior lenses are used, then optical protection and light guidance functions are achieved, but packaging space increases significantly
Solution Approach 1:
The patent combines the exterior lens and interior light guide into a single integrated component. The lens includes an integrated light guide portion that extends from the light source, eliminating the need for separate molded parts. This merging reduces packaging space while maintaining both optical protection and light guidance functions through a unified structure.
2Reliability
If multiple separate optical components are used, then functional requirements are met, but device complexity increases
Solution Approach 1:
The exterior lens and interior light guide are merged into one integral component molded as a single piece. This reduces the number of molded parts from two separate components to one, simplifying the device structure while maintaining all necessary optical functions including light guidance, diffusion, and protection.
Solution Approach 2:
The integrated lens component performs multiple functions simultaneously: it acts as an exterior lens for optical protection, contains an integrated light guide for light transmission, and includes a light exit portion for light emission. This multi-functionality eliminates the need for separate specialized components.
3Ease of manufacture
If separate light guide and lens components are used with air gap, then assembly clearance is provided, but overall thickness increases
Solution Approach 1:
The light guide and lens are merged into a single integrated component with no air gap between them. The integrated structure eliminates the need for clearance spaces while maintaining ease of manufacture through single-mold production. The overall thickness is reduced from 8-18 mm to 4-10 mm or less by eliminating the gap and combining component thicknesses.
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 integration significantly reduces the packaging space required, allowing for a more compact design without additional molded parts or clearance spaces, making it suitable for applications with limited space.
Implementation Method 1
the light guide configured to receive light rays from the light source into the light inlet end, transmit the rays via internal reflectance along light transmission portion
Implementation Method 2
where they are reflected outwardly away from the lighting device in a principal direction through the outer viewable face
Data Source
AI summary
A lighting device includes a housing, the housing comprising an opening. The lighting device also comprises a lens operably disposed in the opening, the lens having an outer viewable face and an opposed inner face, the lens comprising an integrally formed axially-extending light guide, the light guide comprising a light inlet end, a light outlet comprising a portion of the outer viewable face, and a light transmission portion, the light transmission portion comprising a light reflecting structure disposed on the inner face. The lighting device also includes a light source, the light guide configured to receive light rays from the light source into the light inlet end, transmit the rays via internal reflectance along light transmission portion to the light reflecting structures where they are reflected outwardly away from the lighting device in a principal direction through the outer viewable face.