Lighting Module Cover Positioning via Referencing Wall
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Solution Overview
Problem
Existing headlamp lighting modules face challenges in precise positioning of the cut-off edge of the cover, leading to reduced precision in cutting off the light beam and resulting in chromaticism due to manufacturing tolerances and assembly play.
Innovation Solution
The module features a support with a referencing wall and pressing means that allow the cover to be precisely positioned against the second focal point of the collector, eliminating the need for indexing holes and pins, and utilizing a reflective face and ramps for accurate alignment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If indexing holes and pins are used to position the cover, then assembly is simplified, but positioning precision deteriorates due to assembly play
Solution Approach 1:
The patent removes the indexing holes and pins from the assembly, replacing them with a direct pressing mechanism. The cover is positioned by pressing its front face against the referencing wall, eliminating the intermediate positioning elements that caused assembly play and precision loss.
Solution Approach 2:
The cover is pre-positioned by pressing it against the referencing wall before final assembly. This preliminary positioning action ensures the cut-off edge is correctly aligned with the second focal point of the collector before the cover is permanently fixed, preventing positioning errors.
2Strength
If the cover is fixed by screwing with indexing holes, then the cover is securely attached, but the positioning precision of the cut-off edge deteriorates
Solution Approach 1:
The patent eliminates indexing holes and pins, using instead a pressing mechanism that applies force directly to the cover's front face. This removes the source of positioning errors while maintaining secure attachment through the pressing means.
Solution Approach 2:
The cover's front face serves dual purposes: it is both the surface to be pressed against the referencing wall for positioning and the surface that provides the cutting edge. This self-positioning design eliminates the need for separate indexing features.
3Manufacturing precision
If manufacturing tolerances are reduced for hole positioning, then positioning precision improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the indexing holes entirely from the cover design. Instead of requiring precise hole positioning, the cover is manufactured with a simple front face that is pressed against the referencing wall, dramatically reducing manufacturing tolerances and complexity.
Solution Approach 2:
The patent focuses manufacturing precision only where needed - on the front face of the cover that contacts the referencing wall - rather than requiring precision throughout the entire cover, including hole positions. This localized quality approach reduces overall manufacturing complexity.
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
This solution ensures precise positioning of the cut-off edge, improving the accuracy of the light beam cutoff and reducing chromaticism, while simplifying the manufacturing process by eliminating the need for precise positioning holes and pins.
Implementation Method 1
The module also comprises pressing means for pushing the front face of the cover against the support
Implementation Method 2
a reflective face facing away from the active surface of the support
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a lighting module comprising an elliptical collector (10) adapted to reflect a beam (6) from a light source (4) towards an optical element (8). The module includes a cover (12) mounted in the path of the light beam to form a cutoff edge. According to the invention, the light source, the collector, and the cover are mounted on an active surface (26) of a support (2) which also includes a referencing wall (32). Means are provided for attaching the cover to this active surface and for pushing the front face (44) of the cover, which includes the cutoff edge, against this referencing wall (32).