Vehicle Lamp Component Reuse Through Electrical and Illumination Testing
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Solution Overview
Problem
The complexity of modern vehicle lamps makes component replacement difficult, and damaged lamps are often discarded entirely due to the inability to identify reusable parts, leading to increased costs and environmental waste.
Innovation Solution
A method involving electric circuit functionality and illumination tests to identify reusable components, followed by a process to separate and salvage these components without further damage, allowing for remanufacturing into new lamp assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional multi-step manufacturing process is used, then various components can be assembled, but the process requires multiple masking steps and multiple curing cycles which increases manufacturing complexity and time
Solution Approach 1:
The patent combines multiple manufacturing steps into a single injection molding process. The mold includes integrated components (cavity, core, ejector pins, cooling channels) that form the complete lamp housing and socket assembly in one operation, eliminating the need for separate molding, assembly, and curing steps required by conventional methods
Solution Approach 2:
The injection molding process prepares all components (housing, socket, and embedded electrical elements) simultaneously during the single molding cycle. The mold design incorporates pre-positioned ejector pins and cooling channels that automatically perform ejection and cooling functions as part of the primary manufacturing process, rather than requiring subsequent separate operations
2Productivity
If a conventional multi-step manufacturing process is used, then various components can be assembled, but multiple masking steps and multiple curing cycles are required which increases manufacturing time
Solution Approach 1:
The patent merges multiple curing cycles into a single injection molding operation. The thermosetting material cures within the mold during the molding cycle itself, and the integrated mold design allows all components to be cured simultaneously without requiring sequential masking and curing steps
Solution Approach 2:
The injection molding process maintains continuous useful action throughout the manufacturing cycle. The material is injected, packed, cooled, and cured in an uninterrupted sequence within the mold, eliminating the idle time and repeated setup required by conventional multi-step processes with intermediate masking and curing cycles
3Manufacturing precision
If conventional manufacturing methods are used, then components can be assembled separately, but it is difficult to achieve precise alignment and integration of electrical elements
Solution Approach 1:
The patent merges the formation of mechanical housing components and electrical socket elements into a single injection molded part. The mold design integrates the cavity, core, and ejector pin positions to automatically ensure precise alignment of all features, eliminating alignment errors that would result from separate assembly operations
Solution Approach 2:
The mold is segmented into distinct components (cavity, core, ejector pins, cooling channels) that are positioned and fixed relative to each other with high precision. This segmentation allows each element to be independently designed and positioned while maintaining precise spatial relationships, ensuring accurate alignment in the final molded part
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
Enables the identification and reuse of salvaged components, reducing waste and costs by creating lamp assemblies that meet or exceed original specifications.
Implementation Method 1
The injection mold includes a heating system to maintain the injection molding cavity at a temperature between 20°C to 100°C
Implementation Method 2
The molded part is made from a thermosetting resin which has been molded in the injection molding cavity to a predetermined shape. The thermoset material is injected into the injection molding cavity and cured to form a molded part having an integrated electrical socket and lamp housing
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
The present teachings relate to a method for identifying reusable components of a vehicle lamp assembly, the method including: i) performing an electric circuit functionality test on each component of a plurality of components of the vehicle lamp assembly; ii) performing an illumination test on each light source within the vehicle lamp assembly; iii) identifying which of the components of the plurality of components pass and/or fail the electric circuit functionality test; and iv) identifying which light sources pass and/or fail the illumination test.