Modular Light Assembly for Vehicle Accessory Channel
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Solution Overview
Problem
Existing motor vehicle accessory components with integrated lighting face challenges in assembly complexity, cost, and reliability due to exposure to elements, requiring skilled installation and potential water ingress when individual lights and wiring are used.
Innovation Solution
A modular light assembly with a frame and optical elements secured to a structural member featuring a channel, allowing easy insertion and secure positioning within the channel, coupled with electrical cabling for power, simplifying assembly and reducing water ingress risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual lights and associated wiring are installed separately on the accessory component, then the lighting system can be integrated into the accessory component, but the assembly complexity increases significantly and requires skilled installation
Solution Approach 1:
The patent combines multiple individual lights and their associated wiring into a single pre-assembled lighting assembly. This modular unit includes all necessary electrical connections and mounting hardware integrated together, allowing the entire lighting system to be installed as one component rather than assembling multiple separate lights and wires during final installation.
2Reliability
If individual lights are mounted to the accessory component using adhesives or mechanical fasteners, then the lights can be securely attached, but the installation requires skill, care and experience
Solution Approach 1:
The lighting assembly is pre-assembled with all lights and wiring connections made before installation. The entire assembly is tested and prepared in advance, so that during final installation, the pre-assembled unit is simply positioned and secured as a complete package, eliminating the need for skilled workers to perform complex wiring and alignment tasks on the assembly line.
3Productivity
If individual lights are not properly lined up with associated holes or openings during assembly, then assembly can be faster, but excessive water can enter the interior area and compromise lighting system operation
Solution Approach 1:
By integrating all lights, wiring, and sealing components into a single pre-assembled unit, the patent ensures proper alignment and sealing is achieved during the manufacturing of the lighting assembly itself, where precision tools and controlled conditions are available. The complete assembly includes integrated sealing elements that prevent water ingress when properly installed in the accessory component.
4Adaptability or versatility
If the accessory component is designed to accommodate individual lights and wiring, then lighting functionality is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent segments the lighting system into a separate, modular lighting assembly that can be manufactured independently using optimized processes. This allows the lighting components to be produced in a controlled environment with specialized equipment, then sold as a separate unit that integrates into the accessory component, reducing the overall manufacturing complexity and cost.
Data Source
AI summary
The present disclosure relates to a vehicle accessory component for a vehicle. The component makes use of a structural member having a channel. The structural member is attachable to the vehicle. A modular light assembly is included which has a frame and at least one optical element secured to the frame. Electrical cabling couples the optical element to a power source. The frame is insertable into the channel in the structural member and supported within the channel. The frame has at least one opening over which the optical element is positioned when the modular light assembly is inserted into the channel. This allows the optical element to provide illumination to an area adjacent the vehicle when the optical element is powered on.