Light Module Fastening Guide Pin Adhesive Adjustment
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Solution Overview
Problem
Existing light modules for motor vehicle headlights face challenges in precise positioning and stress-free fixing of optically functional components due to temperature variations and the need for precise light beam distribution, which can result in undesirable color fringes and inefficiencies.
Innovation Solution
A light module with a fastening device using a guide pin and guide bushing system that allows for precise adjustment and tension-free fixing of the primary optics unit relative to the light source unit, utilizing an adjustment gap filled with adhesive material to establish an integral connection, enabling precise positioning and stress-free operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid fastening is used to fix the position of primary optics unit relative to light source unit, then positioning precision is improved, but stress and deformation occur due to temperature variations
Solution Approach 1:
The patent changes the physical state of the adhesive material from liquid to solid through curing, transforming the fastening mechanism from mechanical rigid connection to chemical bond connection. This allows the joint to accommodate thermal expansion and contraction while maintaining precise positioning, resolving the contradiction between positioning precision and fastening stress.
2Adaptability or versatility
If adjustable fastening system is used to allow tilting and depth adjustment of primary optics unit, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent segments the fastening function into two independent parts: mechanical positioning through guide pin and guide bushing geometry, and final fixation through adhesive material. This segmentation allows adjustment capabilities to be achieved through simple geometric features rather than complex adjustable mechanisms, resolving the contradiction between adaptability and device complexity.
3Manufacturing precision
If precise positioning is achieved through rigid mechanical connection, then positioning accuracy is improved, but stress-free operation under temperature variations deteriorates
Solution Approach 1:
The adhesive material acts as an intermediary substance between the guide pin and guide bushing, providing both positioning accuracy through the guide geometry and stress-free operation through the flexible bonding properties of the cured adhesive. This intermediary resolves the contradiction between positioning accuracy and reliable stress-free operation under temperature variations.
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 allows for precise adjustment and fixing of the light module components in three spatial directions, preventing undesirable color fringes and ensuring efficient light distribution, even under temperature variations, by allowing for tilting and depth adjustment of the primary optics unit relative to the light source unit.
Implementation Method 1
the adjustment space is at least partially filled with a filling adhesive material in such a way that an integral connection is established between the guide pin and the guide bushing
Data Source
Figure 1
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AI summary
The light module (10) has a primary lens unit (14) that includes an optical element (32) for shaping the light emitted from a light source (26) into an intermediate light distribution. The primary lens unit and a light source unit (12) are fastened by a fastening element (80). An adjusting interstice is engaged with an interior sleeve between a guide pin (82) and a socket inner wall through a pin receiving opening. The interstice is partially connected between the guide pin and a guide sleeve (84) with a filling adhesive material. An independent claim is included for a method of manufacturing a light module.