Universal Lamp Housing Mounting System
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Solution Overview
Problem
Current vehicle lamps require different housing configurations for inset and on-surface mounting modes, leading to the need for multiple lamp models with the same optical design, which is inefficient in manufacturing and application.
Innovation Solution
A system with different mounting members that can engage a common-shaped lamp housing, allowing for both flush and inset mounting modes, using features like continuous flanges and elastomeric materials to secure the housing in various positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different housing configurations are used for inset and on-surface mounting modes, then each mounting mode can be properly accommodated, but multiple lamp models with the same optical design are required, increasing manufacturing complexity
Solution Approach 1:
The lamp housing is designed with a universal mounting interface that can accommodate both inset and on-surface mounting modes. The housing includes a flange with mounting features that work with different mounting members (inset mounting bracket and on-surface mounting bracket), allowing a single housing design to serve multiple mounting applications.
Solution Approach 2:
The mounting system is divided into separate components: the lamp housing with integrated flange, the inset mounting bracket, and the on-surface mounting bracket. This segmentation allows the housing to remain standardized while the mounting brackets are customized for specific installation modes, reducing housing variety while maintaining mounting flexibility.
2Ease of manufacture
If a single housing configuration is used for both inset and on-surface mounting, then manufacturing is simplified, but the housing must accommodate different mounting requirements simultaneously
Solution Approach 1:
The housing incorporates a universal flange design with standardized mounting features (holes, ridges, or recesses) that can interface with different mounting bracket types. This allows the same housing to be used for both inset and on-surface mounting without requiring design variations.
Solution Approach 2:
The flange acts as an intermediary component between the housing and the mounting brackets. It provides standardized interface features that mediate between the housing's fixed geometry and the different mounting requirements, enabling a single housing design to work with multiple mounting configurations.
3Adaptability or versatility
If multiple lamp models are produced for different mounting modes, then each model can be optimized for its specific application, but inventory and selection complexity increases
Solution Approach 1:
A single lamp model with a universal mounting flange replaces multiple lamp models designed for specific mounting modes. The flange's standardized features enable the same lamp to be installed using either inset or on-surface mounting brackets, eliminating the need for separate inventory lines.
Solution Approach 2:
The mounting capabilities for both inset and on-surface applications are merged into a single housing design through the universal flange. This consolidation reduces the total number of lamp models from multiple to one, while maintaining the ability to serve different installation needs.
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 a single lamp housing to be mounted on a vehicle in multiple configurations, reducing the need for multiple lamp models and simplifying manufacturing while maintaining effective light emission and sealing.
Implementation Method 1
a mounting member may be of elastomeric material so as to deform to engage the outer periphery of the housing
Implementation Method 2
The different mounting members each engage a common shape housing of the lamp
Data Source
AI summary
A system is provided for mounting a lamp having a plurality of different types of mounting members. One of the mounting members is a rigid tray mountable by fasteners flush upon a surface of a vehicle to enable an on-surface mounting mode, and other of said mounting members, such as a grommet or bracket, are mountable at least partially in an opening or hole when present along such surface of a vehicle to enable an inset mounting mode. The different mounting members each engage a common shape housing of the lamp, such as round or oval, so that by selection of one of the mounting members, on-surface or inset mounting of the lamp can readily be achieved. One or more common engagement features are provided along the housing to facilitate engagement of the housing of the lamp by mounting members in on-surface and inset mounting modes.