Vehicle Light Module Arm Retention for Optical Stability
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Solution Overview
Problem
The existing light modules for motor vehicle headlamps face issues with the positioning stability of primary optical devices due to manufacturing clearances and variations caused by mechanical vibrations and temperature changes, leading to inconsistent dipped beam patterns that can be hazardous.
Innovation Solution
A light module design featuring an arm projecting from the base to hold the primary optical device at a holding zone between the receiving and exit faces, with complementary members such as grooves and lugs to prevent displacement, and a frame secured to the base to maintain the optical device's position relative to the light source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the primary optical device is positioned with a large overhang from the base to reduce interference with other components, then the compactness of the light module is improved, but the positioning stability deteriorates due to manufacturing tolerances and mechanical vibrations causing inclination changes
Solution Approach 1:
The patent introduces a retaining arm that extends from the base in a direction perpendicular to the optical axis, creating a new spatial dimension for support. This arm provides lateral stabilization of the primary optical device without increasing the overhang distance along the optical axis, thus maintaining compactness while improving positioning stability through multi-dimensional structural support
Solution Approach 2:
The retaining arm acts as an intermediary element between the base and the primary optical device. It provides an additional support interface that compensates for positioning errors caused by manufacturing tolerances and mechanical vibrations, stabilizing the optical device's inclination without requiring changes to the base or optical device themselves
2Manufacturing precision
If manufacturing tolerances are reduced to improve positioning precision of the primary optical device, then the beam pattern consistency is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The retaining arm is designed to automatically compensate for positioning deviations through its elastic deformation capability. When the primary optical device is installed, the arm self-adjusts its position to accommodate manufacturing tolerances, eliminating the need for precision machining or complex adjustment mechanisms while maintaining beam pattern consistency
Solution Approach 2:
The patent utilizes the elastic properties of the retaining arm material, changing the physical parameter of flexibility to absorb positioning variations. By selecting appropriate material properties and arm dimensions, the system tolerates manufacturing imperfections without affecting the final positioning accuracy of the primary optical device
Data Source
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AI summary
A lighting module for the illumination and/or signaling of a motor vehicle comprises a base (10) supporting, on one of its faces, at least one light source emitting light rays extending predominantly along an optical axis perpendicular or substantially perpendicular to the first face, and a primary optical device (50) comprising a receiving portion opposite at least one portion of the light source and an output face (54) opposite the receiving portion. The lighting module includes at least one arm (36) projecting from the first face of the base (10) and holding the primary optical device (50) at a retention zone (62) located between the receiving portion and the output face (54) of the primary optical device (50).