Vehicle Lighthead Mounting System with Rear Fastening
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Solution Overview
Problem
Existing lighthead systems for motor vehicles require multiple threaded fasteners for assembly and mounting, which compromise the light-emitting surface area, aesthetic appearance, and interfere with automated assembly, while also failing to meet durability and regulatory standards for extreme environmental conditions.
Innovation Solution
A mounting system that minimizes the use of fasteners by employing a frame with movable engagement features and a bezel that snaps together with the lighthead, using tool-free or conventional fasteners to secure the assembly without interrupting the light-emitting face, and includes a gasket for environmental sealing, allowing for customizable appearance and automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded fasteners are used to secure the lighthead to the motor vehicle, then the lighthead is firmly mounted, but the light-emitting surface area is reduced and aesthetic appearance is compromised
Solution Approach 1:
The patent extracts the fastener from the light-emitting face by positioning it on the rear surface only. The clamp assembly includes a rear surface with a recess that receives a fastener, allowing the fastener to secure the lighthead to the vehicle without being visible from or interfering with the light-emitting front surface.
Solution Approach 2:
The patent moves the fastener from the two-dimensional light-emitting face to the three-dimensional rear surface of the lighthead. This spatial relocation allows the fastening function to be performed without compromising the aesthetic and functional light-emitting surface.
2Reliability
If multiple threaded fasteners are used for assembly and mounting, then the lighthead is securely retained, but automated assembly is interfered with and manufacturing complexity increases
Solution Approach 1:
The patent extracts the threading requirement from the fastening system by providing a recess in the rear surface that can receive various fastener types. This design allows for simplified fasteners that can be automatically inserted and secured, eliminating complex threaded fastening operations that hinder automated assembly.
Solution Approach 2:
The clamp assembly design with the rear surface recess can accommodate multiple types of fasteners (screws, bolts, rivets, or automated push-fasteners), making the system universal and adaptable to different assembly methods including automated processes.
3Strength
If threaded fasteners are used for housing component assembly, then structural integrity is maintained, but the number of fasteners increases and assembly time increases
Solution Approach 1:
The patent extracts the fastener from the light-emitting face and consolidates it to the rear surface only. This reduces the total number of fasteners needed while maintaining structural integrity through the clamp assembly design that distributes mounting forces across the rear surface and housing components.
Solution Approach 2:
The patent merges the functions of securing housing components and mounting the lighthead to the vehicle into a single rear-surface fastening system. The clamp assembly integrates both housing retention and vehicle mounting functions, reducing the total fastener count and assembly steps.
4Reliability
If fasteners pass through the light-emitting surface, then secure mounting is achieved, but aesthetic appearance is detracted
Solution Approach 1:
The patent extracts the fastener from the visible light-emitting surface and relocates it to the hidden rear surface. The rear surface includes a recess that conceals the fastener, allowing secure mounting to be achieved without compromising the aesthetic appearance of the front light-emitting face.
Data Source
AI summary
According to aspects of the disclosure, the system comprises a frame mounted in sealed relation to a surface. The frame includes movable engagement features and surfaces that mate with an accessory body. A gasket positioned between the frame and a mounting surface seals the space between the frame and the mounting surface from surrounding external elements. The frame may be fastened to the mounting surface with tool-free rivet fasteners, or more conventional threaded fasteners. The assembled accessory body and bezel fit over the frame and the movable engagement features of the frame mate with complementary structures on the accessory body to fix the accessory body to the frame. Openings in the accessory body allow a threaded fastener to secure the movable engagement feature of the frame in the mated position, preventing unintentional disengagement of the accessory body.