Motor Vehicle Lighting Assembly With Integrated Pin-Cavity Joining

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Solution Overview

Problem

Existing lighting assemblies for motor vehicles face challenges in precise adjustment and assembly due to the use of separate fastening units, which increase component count, weight, size, and assembly time, and introduce contamination risks.

Innovation Solution

Integrate fastening means, such as pins and cavities, into primary components like the lens holder and heat sink element, eliminating the need for separate fastening units, and utilize adhesive joints for precise alignment and assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate fastening units with screws and threaded holes are used to join modules, then mechanical strength and reliability of connection is improved, but device complexity and number of components increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates the fastening function directly into the primary structural components (lens holder and heat sink element) by incorporating pins and cavities as integral features rather than separate fastening units. This merging eliminates the need for distinct fastening components while maintaining connection reliability through adhesive joints applied to the integrated pin-cavity interfaces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lens holder and heat sink element serve multiple functions: they provide structural support, thermal management, and simultaneously serve as fastening components through their integrated pins and cavities. This multi-functionality reduces the overall component count while maintaining all necessary mechanical functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If separate fastening units are used to join modules, then mechanical strength of connection is improved, but weight and size of the assembly increases

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

By combining the fastening function into the existing structural components, the patent eliminates redundant material. The pins and cavities are formed as integral features of the lens holder and heat sink element, removing the weight of separate fastening units while maintaining connection strength through adhesive bonding.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If separate fastening units with screws and threaded holes are used, then mechanical strength is improved, but assembly time and manufacturing effort increases

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The pins and cavities are pre-formed as integral features of the lens holder and heat sink element during their respective manufacturing processes. This preliminary action eliminates the need for separate fastening component installation steps, reducing assembly time while maintaining connection strength through adhesive application to the pre-positioned pin-cavity interfaces.

Inventive Principle:

Principle #10Preliminary action

4Strength

If threaded holes are drilled into modules for screw joints, then mechanical strength is improved, but risk of contamination with dust or debris increases

Engineering Contradiction:

Improveconnection strengthVSAvoidcontamination risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the harmful drilling operation from the assembly process by eliminating the need for threaded holes. Instead of creating holes that expose the interior to contamination, the design uses externally formed pins and cavities that can be joined via adhesive application without penetrating into the module interiors, thereby removing the contamination source.

Inventive Principle:

Principle #2Taking out (Extraction)

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 component count, improves handling efficiency, and enhances weight, dimensional tolerance, and vibration characteristics while ensuring precise alignment and reduced assembly time.

Implementation Method 1

The objective module and the light source module are joined by means of adhesive joints between the first pins and the first cavities

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

at least one light source mounted on a heat sink element

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4139608B1Lighting assembly for a lighting device of a motor vehicle

Publication Date: 2025.10.01 HELLA GMBH & CO KGAA

Figure 1

AI summary

The invention relates to a lighting assembly (100) for a lighting device (200) of a motor vehicle, the lighting assembly (100) comprising an objective module (1) with at least one objective lens (11) mounted in a lens holder (10) and with at least two first pins (12), the lighting assembly (100) further comprising a light source module (2) with at least one light source (21) mounted on a heat sink element (20) and with at least two first cavities (22), wherein the objective module (1) and the light source module (2) are joined by means of adhesive joints between the first pins (12) and the first cavities. According to the invention, the lens holder (10) comprises the first pins (12) and/or the heat sink element (20) comprises the first cavities (22).