Luminous Vehicle Emblem Cover Structure for Scratch-Free Welding
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Solution Overview
Problem
Existing luminous emblems suffer from scratches on their decorative surfaces due to contact with welding tools during assembly, affecting their aesthetic appearance.
Innovation Solution
A vehicle exterior component design featuring a resin housing with an open portion, a cover welded to its peripheral edge, and a frame that includes a light-transmitting and light-shielding decorative member, where the decorative member is laminated onto the cover's surface and the frame is bonded to the housing, protecting the decorative surface from scratches and ensuring aesthetic integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer lens is welded to the housing using ultrasonic welding, then the bonding strength is improved, but the decorative surface is scratched by the horn or anvil
Solution Approach 1:
A resin frame is introduced as an intermediary component between the housing and the outer lens. The frame includes a light-transmitting portion that transmits light and a light shield portion that blocks light. The frame is positioned such that it contacts the housing during welding while the outer lens remains protected, preventing direct contact between welding tools and the decorative surface.
Solution Approach 2:
The cover structure is divided into multiple functional portions: a light-transmitting portion for light transmission, a light shield portion for light blocking, and a frame portion for structural support and welding interface. This segmentation allows each portion to perform its specific function while protecting the overall assembly.
2Shape
If paint or plating is applied to the outer lens surface to create opaque regions, then the aesthetic appearance is improved, but the surface becomes vulnerable to scratches during welding
Solution Approach 1:
The outer lens is constructed as a composite structure combining a light-transmitting resin base with a decorative member that has light-shielding properties. This composite structure achieves the desired aesthetic appearance while the resin frame provides protective contact surfaces during welding, preventing damage to the decorative surfaces.
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 design maintains the aesthetic appearance of the luminous emblem by preventing scratches on the decorative surface and reducing the likelihood of decorative member separation, while also enhancing bonding strength and reducing light leakage.
Implementation Method 1
a light source, a resin housing including an open portion open toward an outer side of a vehicle and accommodating the light source
Implementation Method 2
a resin frame bonded to a peripheral edge of the cover
Implementation Method 3
a cover welded to a peripheral edge of the housing and closing the open portion
Data Source
AI summary
The vehicle exterior component includes a light source, a resin housing that includes an opening portion and accommodates the light source, and a cover welded to a peripheral edge of the housing. The cover includes a cover body and a resin frame bonded to a peripheral edge of the cover body. The cover body includes a resin base that has visible light transmittance and a decorative member laminated onto an outer surface of the base. The decorative member includes a light-transmitting portion that transmits visible light and a light shield portion that blocks visible light. The frame includes a part of an outer surface of the cover that overlaps with the peripheral edge of the housing in an opening direction of the open portion.