Lamp Unit Housing with Nested Wall Portions for Contaminant Protection
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Solution Overview
Problem
Lamp units with exposed luminous elements, such as LEDs, face issues with foreign substance invasion through openings, leading to reduced illumination intensity and appearance quality, particularly in vehicle interior map lamps where dust easily enters.
Innovation Solution
A lamp unit design where the housing is sandwiched and fixed between a substrate and a lens, with protruding wall portions surrounding the opening, preventing foreign substance invasion and enhancing light emission efficiency without using separate fixing members, and incorporating light diffusion processing to reduce color unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the lens is exposed from an opening in the housing, then light emission efficiency is improved, but foreign substances invade the housing and attach to the luminous element or rear face of the lens, lowering illumination accuracy and appearance quality
Solution Approach 1:
The housing is divided into multiple wall portions (first wall portion, second wall portion, third wall portion) that collectively surround the opening. This segmentation allows the housing to maintain an exposed lens configuration for light emission while creating multiple barriers against foreign substance invasion, resolving the contradiction between light emission efficiency and protection from contaminants.
Solution Approach 2:
The first wall portion, second wall portion, and third wall portion are nested together to form a multi-layered protective structure around the opening. The first wall portion protrudes from the housing, the second wall portion protrudes from the substrate, and the third wall portion connects them, creating nested layers that block foreign substances while allowing light to pass through the exposed lens.
2Ease of manufacture
If a conventional housing structure with opening is used, then manufacturing is simple, but foreign substances attach to the luminous element or rear face of the lens, lowering illumination accuracy
Solution Approach 1:
The housing structure is segmented into multiple wall portions that can be manufactured separately and then assembled. This segmentation maintains manufacturing simplicity while ensuring that each wall portion contributes to blocking foreign substances, thereby preserving illumination accuracy without requiring complex single-piece housing manufacturing.
Solution Approach 2:
The multiple wall portions are nested together to form a protective structure that prevents foreign substance invasion. This nested configuration maintains relative manufacturing simplicity compared to complex sealing mechanisms, while effectively protecting the luminous element and lens rear face to ensure illumination accuracy.
3Shape
If the lens is exposed from the housing, then appearance quality may be good, but foreign substances attach to the luminous element or rear face of the lens, lowering appearance quality
Solution Approach 1:
The housing is segmented into multiple wall portions that create a protective barrier while maintaining the lens exposure configuration. The first wall portion, second wall portion, and third wall portion work together to block foreign substances from reaching the lens rear face and luminous element, preserving appearance quality without obscuring the lens.
Solution Approach 2:
The nested arrangement of multiple wall portions creates layered protection around the opening. This nested structure prevents foreign substance attachment to the lens and luminous element while maintaining the aesthetic lens exposure configuration, as the wall portions are positioned to block contaminants without obstructing the visible lens surface.
Data Source
AI summary
A lamp unit, comprises a substrate on which a luminous element is mounted, a housing having an opening in which the luminous element is arranged, and a lens arranged at a light emitting side of the luminous element, wherein the housing is sandwiched and fixed between the substrate and the lens; and wherein the lens is provided with a first wall portion protruding from a side of the lens facing the housing and surrounding the opening of the housing, and the housing is provided with a second wall portion protruding from a side of the housing facing the substrate and surrounding the opening of the housing.