Integrated Light Bar Projector Assembly With Shared Wire Harness
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Solution Overview
Problem
Existing vehicle light systems require multiple components and wires, increasing cost, weight, and complexity, while also making it difficult to add projectors to existing vehicles.
Innovation Solution
A light assembly that integrates a projector directly with a light bar, sharing power and control wires, and featuring a sealed light assembly with a customizable lens stack for projecting patterns or logos onto the ground.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a projector is integrated with a light bar to reduce parts and cost, then the number of parts and cost are reduced, but the complexity of wire harness integration increases
Solution Approach 1:
The patent combines the projector and light bar into a single integrated assembly, sharing common components including the wire harness. The projector is mounted directly on the light bar housing, and both devices share power and control wiring through a common wire harness, reducing the total number of parts while managing integration complexity through unified design
Solution Approach 2:
The wire harness is designed to serve multiple functions simultaneously - it provides power and control signals to both the light bar and the projector through shared connections. The system uses a universal mounting structure that can accommodate different projector configurations, and the control system can operate both devices with unified control logic
2Ease of operation
If multiple separate components are used for projector and light bar, then ease of installation is improved, but weight and cost increase
Solution Approach 1:
The projector and light bar are combined into a single integrated unit that mounts to the vehicle as one assembly. The common wire harness and shared mounting structure reduce the total number of installation steps, while the integrated design eliminates redundant components, reducing overall weight without compromising installation ease
3Reliability
If a sealed light assembly is used to protect components, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The light assembly uses a nested sealed structure where the projector is housed within the light bar housing, and both are protected by a common sealed enclosure. The wire harness is routed through sealed channels within the housing, and connectors are sealed to prevent moisture ingress. This nested sealing approach protects all components reliably while using standard manufacturing techniques for enclosed assemblies
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
This integrated solution reduces the number of parts and wires, lowering vehicle costs and weight while enabling easy installation of projectors on existing vehicles, with the added benefit of customizable light patterns.
Implementation Method 1
The lens stack may have minimized or reduced heights size and include a customizable image slide wherein the customizable image slide enables customization with preferred logos and/or patterns for projection onto a ground surface. In some embodiments, the lens stack comprises a collimation lens set, an image slide, and a zoom and aberration lens set.
Implementation Method 2
The lens stack comprises a collimation lens set, an image slide, and a zoom and aberration lens set
Data Source
AI summary
A light assembly having a projector integrally connected to a light bar. The projector and the light bar share power and control wires from a wire harness. The projector includes a projector aperture whereby light (oftentimes in a pattern or logo formation) passes therethrough and directs onto a ground surface. The projector includes a light assembly configured to hold the components for projection.