Vehicle Lamp Socket Recess Design for Position Accuracy

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Solution Overview

Problem

The existing lamp units face issues with light distribution failures due to deformation of the socket unit during injection molding, which affects the positioning of the heat radiation member and subsequently the light source, leading to improper light distribution in vehicle lamps.

Innovation Solution

A lamp unit design featuring a socket with a recess extending along the back surface of the metal plate, which is supported by a mold to prevent positional deformation, and a connector extending orthogonally to the mounting direction of the light source, ensuring accurate light distribution by minimizing the impact of heat conductive resin shrinkage during molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the socket unit is formed by injection molding with heat conductive resin to integrate the heat radiation member, then the heat radiation efficiency is improved, but deformation and distortion of the socket unit occur due to resin shrinkage, causing position shifts

Engineering Contradiction:

Improveheat radiation efficiencyVSAvoidposition accuracy of heat radiation member

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The socket unit is divided into two separate components: the socket body and the heat radiation member (metal plate). This segmentation allows each component to be manufactured independently with appropriate materials and processes, avoiding the deformation issues that arise from attempting to integrate them through injection molding. The heat radiation member can be precisely positioned and fixed without suffering from resin shrinkage effects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat radiation member (metal plate) is extracted from the integrated socket structure and treated as a separate component. This extraction allows the metal plate to be independently manufactured with high precision and then securely fixed to the socket body, eliminating the position shifts that occur when heat radiation members are formed through injection molding with resin shrinkage.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If the connector extends from the side surface of the socket in a direction different from the mounting direction of the light source, then the adaptability to different lamp body locations is improved, but the mold cannot properly support the metal plate during injection molding, causing position shifts

Engineering Contradiction:

Improveadaptability to lamp body locationsVSAvoidposition accuracy of metal plate

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

By separating the socket body from the heat radiation member, the design allows the connector to extend in various directions (including from side surfaces) without compromising the positioning accuracy of the metal plate. The segmented structure enables independent optimization of both the connector layout for adaptability and the metal plate fixation for precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal plate is prepared and positioned in advance before final assembly with the socket body. This preliminary positioning ensures that regardless of how the connector is oriented for adaptability to different lamp body locations, the metal plate maintains its correct position for light source mounting.

Inventive Principle:

Principle #10Preliminary action

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

The solution effectively suppresses light distribution failures by maintaining the correct positioning of the light source and heat radiation member, ensuring consistent and desired light distribution in vehicle lamps.

Implementation Method 1

a heat radiation member such as a metal plate that is brought into contact with the light source

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a heat radiation member such as an aluminum plate is brought into contact with the light source unit to radiate the heat of the light emitting element

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 3

increase the surface area in order to increase the heat radiation efficiency

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11156338B2Lamp unit, vehicle lamp, and method for manufacturing lamp unit

Publication Date: 2021.10.26 KOITO MFG CO LTD

AI summary

A lamp unit includes a light source, and a socket on which the light source unit is mounted. The socket includes a light source holder that holds the light source, and a connector that supplies power to the light source, and the light source holder includes a recess extending along a light source unit mounting surface from an outside to a portion immediately below the light source.