Automotive Lighting Cap Positioning via Elastic Lock Lever

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Solution Overview

Problem

Current lighting arrangements in automotive applications face challenges with precise positioning of exchangeable lighting caps, leading to positive play between components, increased production costs due to spring mechanisms, and optical interruptions in the light beam pattern.

Innovation Solution

A lighting arrangement featuring an exchangeable lighting cap with positioning slots and a lock lever that allows for elastic deformation to achieve a tight fit, eliminating the need for elaborate spring mechanisms and ensuring precise positioning without optical interruptions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a spring-loaded system is used to hold the lighting cap in position, then the lighting cap can be held securely, but the system becomes more complex and expensive to produce

Engineering Contradiction:

Improvepositioning accuracyVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the spring mechanism from the positioning system, extracting the complex elastic element while maintaining positioning accuracy through a simplified geometry-based locking system using the lock lever and positioning slots

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using an active spring force to maintain positioning, the invention uses a passive geometric locking mechanism where the lock lever engages with positioning slots to define and maintain the correct position through its own geometry rather than elastic deformation

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If a spring mechanism is used to hold the lighting cap, then positioning is achieved, but production costs increase

Engineering Contradiction:

Improvepositioning precisionVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive spring mechanisms with simple, inexpensive geometric features (positioning slots and lock lever engagement points) that can be easily manufactured into the lighting cap and holder using standard molding techniques

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The positioning function is segmented into discrete geometric features (two positioning slots at specific locations) rather than requiring a continuous spring mechanism, allowing for simpler manufacturing and assembly

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If a large axial mating reference plane is used for alignment, then positioning is achieved, but optical definition and cut-out zones are interrupted

Engineering Contradiction:

Improvealignment accuracyVSAvoidoptical definition

Core Design Contradiction:

Manufacturing precisionVSIllumination intensity

Solution Approach 1:

The patent moves the alignment reference from a large axial plane to point-based positioning slots located at the periphery, changing the dimension of the reference feature from two-dimensional to zero-dimensional (point contacts), thereby eliminating optical interruptions

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Instead of using a large reference plane that interrupts the optical path, the invention uses localized positioning slots at specific peripheral locations that provide alignment functionality without interfering with the central optical definition and light beam pattern

Inventive Principle:

Principle #3Local quality

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 enables precise and repeatable positioning of the lighting cap, reduces production costs, and minimizes unwanted changes in the beam pattern, making it suitable for various automotive lighting applications.

Implementation Method 1

the positioning elements can be inserted into the positioning slots of the lighting cap by elastic deformation of the holder or of the lighting cap to fix the position of the lighting cap on the holder by a tight fitting

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentEP3538815B1Lighting arrangement with an exchangeable lighting cap

Publication Date: 2022.04.13 LUMILEDS LLC

Figure 1
Figure 2a~2b
Figure 2c

AI summary

A lighting arrangement (10) with an exchangeable lighting cap (20), a holder (30) for the lighting cap (20) and a lock lever (40) to lock the lighting cap (20) in position on the holder (30) is described. At least one light emitting element (21) is arranged on a front face (22) of the lighting cap (20), emitting light at least in a direction of illumination perpendicular to the front face (22). Additionally, at the edge (24) of the front face (22) of the lighting cap (20) two positioning slots (23 a, b) are arranged in an alignment perpendicular to the direction of illumination. The holder (30) comprises an opening (31) for receiving at least the front face (22) of the lighting cap (20) and two positioning elements (33 a, b) are arranged at a rim (32) of the opening (31), wherein the positioning elements (33a, b) can be inserted into the positioning slots (23a, b) of the lighting cap (20) by elastic deformation to fix the position of the lighting cap (20) on the holder (30). Further, a lock lever (40) is arranged at the lighting cap (20) and at the holder (30), wherein the lock lever (40) can be turned between an open position for inserting the lighting cap (20) into the opening (31) of the holder (30) and a locked position for locking the lighting cap (20) in position on the holder (30).