Laminated Lighting Device Housing Segmentation
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Solution Overview
Problem
Existing headlamps and similar light devices face challenges in manufacturing complexity, high costs, fragility, and difficulty in assembly, along with limited modifiability for different activities.
Innovation Solution
A light device with a laminated structure composed of superimposed parts, including a rear base, optical unit, and front bezel, using machined metallic and plastic components, allowing for easy assembly and modification, and featuring a removable battery housing for adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic housing is used for the light block, then manufacturing is simplified through molding, but the housing becomes fragile and assembly remains complex
Solution Approach 1:
The light block housing is divided into multiple separate components (front housing, rear housing, optical unit) that are assembled together using mechanical fastening. This segmentation allows each part to be manufactured independently using simple processes while the assembled structure provides enhanced robustness compared to a single molded plastic housing.
2Ease of manufacture
If a molded plastic housing is used, then manufacturing process is simplified, but manufacturing cost increases due to complex mold creation
Solution Approach 1:
By dividing the housing into multiple simple components that can be manufactured using basic machining or forming processes, the need for complex multi-cavity molds is eliminated. Each component can be produced with simple tools, significantly reducing mold creation costs while maintaining manufacturing simplicity.
Solution Approach 2:
Multiple independently manufactured housing components are assembled together to form the complete light block housing. This merging of simple parts achieves the functional complexity of a molded housing without requiring complex molding tools, thereby reducing manufacturing infrastructure costs.
3Ease of operation
If the light block is made as a single integrated unit, then assembly is simplified, but modifiability for different activities is reduced
Solution Approach 1:
The light block is designed as an assembly of modular components (front housing, rear housing, optical unit, battery compartment) that can be easily separated and reconfigured. This segmentation enables quick modification for different activities by swapping components while maintaining simple assembly procedures using standardized fastening mechanisms.
Solution Approach 2:
The housing components are designed with dynamic assembly and disassembly capabilities through threaded fasteners and removable joints. This allows the structure to transition between integrated and separated states, enabling both simple assembly when needed and easy modification when adaptability is required.
4Productivity
If conventional molding processes are used, then production efficiency is high, but the light block becomes fragile and assembly is complex
Solution Approach 1:
The housing is segmented into multiple components that can be manufactured using high-speed machining or forming processes. This segmentation allows each part to be produced efficiently while the mechanical assembly of these parts creates a more robust structure than a single molded piece, resolving the contradiction between production efficiency and structural robustness.
Data Source
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Figure 6A~7
AI summary
The invention relates to a light block (41) for a light device (4) of a lamp, said light block being composed of a layered structure formed by the superposition of several independent and assembled parts, said parts comprising: - A rear base (42) having a recess forming a housing (422), at least one electronic board (43) fitting into said housing (422) and carrying at least one light source and a control unit for said light source, - An optical block (44) arranged on the rear base to close its housing in a watertight manner by compressing a sealing gasket arranged between said rear base (42) and said optical block (44), - A front bezel (45) arranged on the optical block (44) and having a cutout partially traversed by the optical block.