Automotive Interior Light Trough Assembly With Integrated Leak Seals
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Solution Overview
Problem
Existing methods for forming light engine assemblies for vehicle trim panels often result in light leakage due to inadequate sealing, leading to inefficiencies in light retention and energy conservation.
Innovation Solution
A method involving the injection of a light trough material and a seal material into a mold, where the seal material is compatible but distinct from the light trough material, forming a unitary bond to prevent light leakage, and incorporating end caps and heat stakes for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If existing sealing methods are used for light engine assemblies, then the assembly process is simple, but light leakage occurs and energy retention is poor
Solution Approach 1:
The patent applies composite materials by combining a light trough material (first material) with a seal material (second material) that has different properties. The seal material is specifically selected to be compatible with but distinct from the light trough material, creating a composite sealing structure that effectively prevents light leakage while maintaining manufacturing feasibility.
Solution Approach 2:
The patent merges the sealing function directly into the light trough structure by forming seals as integral parts of the light trough assembly. The seals are formed within the same mold cavity as the light trough, creating a unitary structure that combines light guidance and light containment functions, thereby preventing light leakage without requiring separate complex sealing components.
2Loss of energy
If separate sealing components are added to prevent light leakage, then light retention improves, but manufacturing complexity increases
Solution Approach 1:
The sealing components are merged with the light trough structure by forming them as integral parts within the same mold cavity. This integration allows the light trough and seals to be manufactured as a single unitary component, eliminating the need for separate assembly steps and reducing manufacturing complexity while effectively preventing light leakage.
Solution Approach 2:
The seals are formed in advance within the mold cavity during the light trough manufacturing process itself. By preliminary forming the seals as part of the light trough structure before ejection, the patent eliminates subsequent sealing assembly steps, simplifying the overall manufacturing process while ensuring effective light containment from the outset.
3Reliability
If a unitary light trough part with integrated seals is formed, then light leakage is prevented and energy efficiency improves, but the molding process becomes more complex
Solution Approach 1:
The patent employs composite materials by injecting two different materials into the mold cavity in sequence: first the light trough material, then the seal material. This multi-material injection molding process creates a unitary part with integrated sealing features, ensuring reliable light containment while managing the increased molding process complexity through systematic material injection sequences.
Solution Approach 2:
The light trough structure is preliminarily formed first, followed by the formation of seals within the same mold cavity. This sequential forming approach allows the light trough geometry to be established before adding the sealing features, ensuring proper structural integrity while achieving integrated sealing in a single molding operation.
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 method effectively retains light within the light trough, conserving energy by preventing leakage and ensuring a secure, efficient light engine assembly for vehicle trim panels.
Implementation Method 1
cooling one of the light trough material and the seal material to form a bond between the light trough material and the seal material
Implementation Method 2
cooling one of the light trough material and the seal material to form a bond between the light trough material and the seal material
Data Source
AI summary
A method for forming a light engine assembly includes the steps of injecting a light trough material into a mold, thereby forming a light trough including a trough body having an edge, and injecting a seal material into the mold, thereby forming a seal configured to bond with the edge of the trough body. The method further includes cooling one of the light trough material and the seal material to adhere the light trough material to the seal material, thereby forming a unitary light trough part, ejecting the light trough part, and coupling a lighting unit with the light trough part.