Rear View Logo Lamp Module Resin Fixing for Anti-Rattle Assembly
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Solution Overview
Problem
Existing logo lamp modules for external rear view assemblies of motor vehicles suffer from movement and rattle of the logo sheet or image substrate, which is exacerbated by size variations in molded plastic lenses and the brittleness of glass substrates, making friction fits impractical and automated assembly challenging.
Innovation Solution
A logo lamp module design that incorporates a flow path through a hole in the printed circuit board and a funnel on the first lens, allowing a resin or adhesive to flow and seal the connection between the printed circuit board and the housing, thereby fixing the logo sheet or image substrate in place without additional assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If friction fit is used to prevent rattling of lenses and image substrate, then stability is improved, but manufacturing complexity increases and automated assembly becomes difficult
Solution Approach 1:
The patent extracts the sealing and fixing function from the mechanical friction fit between components and transfers it to a resin material that fills the cavity. The resin is applied separately and provides both sealing and anti-rattle functions, eliminating the need for precise friction fit design and enabling automated assembly.
Solution Approach 2:
The resin acts as an intermediary substance between the printed circuit board, lenses, and image substrate. Instead of relying on direct mechanical contact (friction fit), the resin mediates the connection by filling gaps and providing adhesive bonding, thereby preventing rattling while accommodating dimensional variations.
2Ease of manufacture
If clearance is provided between stack components for automated assembly, then ease of manufacture is improved, but stability deteriorates due to movement and rattle
Solution Approach 1:
The resin serves as a mediator that allows clearance between components for automated assembly while simultaneously preventing movement and rattle. The liquid resin flows into the clearance spaces and, upon curing, locks the components in place, combining the benefits of both clearance and stability.
Solution Approach 2:
The patent changes the physical state of the sealing material from solid (requiring friction fit) to liquid resin that can flow and adapt. This parameter change allows the resin to fill clearance spaces during automated assembly and then solidify to prevent movement, resolving the contradiction between assembly ease and stability.
3Manufacturing precision
If glass image substrate is used, then optical quality is improved, but ease of manufacture worsens due to brittleness and difficulty in friction fit
Solution Approach 1:
The resin acts as a protective intermediary between the brittle glass image substrate and the mechanical assembly process. Instead of relying on friction fit that could damage the glass, the resin provides gentle adhesive bonding that secures the glass substrate without requiring high clamping forces, thereby enabling easier manufacture while maintaining optical quality.
4Strength
If lens stack components are rigid, then structural integrity is improved, but adaptability worsens due to size variation preventing simple snap fit
Solution Approach 1:
The patent changes the state of the bonding material from rigid mechanical contact to a flowable resin that can adapt to size variations. The rigid lens components maintain their structural integrity while the resin accommodates dimensional tolerances by flowing into gaps and providing compliant bonding, thereby enabling adaptability without sacrificing strength.
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 effectively seals and fixes the logo sheet or image substrate, preventing movement and rattle, while allowing for greater variation in assembly and enabling automated assembly without the risk of jamming or increased cycle time.
Implementation Method 1
A logo lamp module design that incorporates a flow path through a hole in the printed circuit board and a funnel on the first lens, allowing a resin or adhesive to flow and seal the connection between the printed circuit board and the housing, thereby fixing the logo sheet or image substrate in place
Data Source
AI summary
The present disclosure relates to a logo lamp module for an external rear view assembly of a motor vehicle comprising a projection optics lens stack arranged within a stack holding portion of a housing closed by a printed circuit board, wherein the projection optics lens stack comprises a logo sheet or image substrate between at least one first lens and at least one second lens, with the at least one first lens being arranged between the printed circuit board and the logo sheet or image substrate, and the at least one second lens being arranged between the logo sheet or image substrate and a light exiting portion of the housing. The logo lamp module further comprises a flow path which is provided by a hole through the printed circuit board and a funnel added to the at least one first lens such that a resin or adhesive applied on the outer surface of the printed circuit board contacts the surface of the logo sheet or image substrate facing the at least one first lens to seal the connection of the printed circuit board and the housing as well as to fix the logo sheet or image substrate within the housing. In addition, the present disclosure relates an external rear view assembly with such a logo lamp module and a motor vehicle with such an external rear view assembly.