Light Assembly Lens Integration for Space and Fastener Reduction
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Solution Overview
Problem
Existing light assemblies for vehicles lack efficient space utilization and cost-effective solutions for integrating multiple light modules, leading to increased fasteners, tooling costs, and assembly time.
Innovation Solution
A light assembly design that includes a housing and a lens with a first light module and a second light module, where the second light module is integrated into the lens, allowing for space savings and reduced fasteners by extending portions outwardly from the lens, maximizing packaging space and using a light pipe to transmit light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple light modules are housed in separate spaces behind the outer lens, then each light module can be independently positioned and maintained, but the space utilization is inefficient and the assembly requires more fasteners and tooling
Solution Approach 1:
The patent integrates the second light module directly into the lens structure, merging two previously separate components (lens and light module housing) into a unified assembly. This eliminates the need for separate mounting spaces and fasteners for the second light module, improving space utilization while reducing assembly complexity
Solution Approach 2:
The lens is designed to serve multiple functions: it acts as both the optical element for light transmission and as the housing structure for the second light module. This multi-functionality eliminates the need for separate housing structures, reducing the number of fasteners and tooling requirements while maximizing space utilization
2Productivity
If the second light module is integrated into the lens, then space requirements are reduced and assembly time is minimized, but the manufacturing precision requirements increase
Solution Approach 1:
The second light module is pre-integrated into the lens structure during lens manufacturing, rather than being assembled separately. This preliminary integration ensures precise positioning and alignment are built into the component itself, reducing the need for high-precision assembly operations and tooling while minimizing assembly time
Solution Approach 2:
The patent uses the lens material and structure as an intermediary that inherently provides precise positioning and alignment for the second light module. The integrated design allows the lens itself to serve as the mounting structure, eliminating the need for separate fasteners and complex alignment procedures while maintaining manufacturing feasibility
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 integrated design reduces space requirements, minimizes fasteners and assembly time, and provides an aesthetically pleasing appearance while maintaining effective light transmission and control.
Implementation Method 1
a first light module disposed in the interior region and selectively operable to emit light that is transmitted through the lens
Implementation Method 2
using a light pipe to transmit light
Data Source
AI summary
The present disclosure provides a light assembly including a housing and a lens secured to the housing. The lens cooperates with the housing to define an interior region therebetween. The light assembly also includes a first light module disposed in the interior region. The first light module is selectively operable to emit light that is transmitted through the lens. The light assembly further includes a second light module selectively operable to emit light that is transmitted through the lens. At least a portion of the second light module is integrated into the lens.