Multifunction Lamp Unit with 3-Component Injection Molding
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Solution Overview
Problem
The existing lamp designs for vehicles, particularly side-view mirrors, are costly and limited in design flexibility due to the need for weld seams or adhesive seams, which also affect the tolerances of adjacent clearances and complicate the integration of lighting functions.
Innovation Solution
A multifunction lamp unit with a housing, light conductor, and clear lens produced through a 3-component injection process, where the refractive indices of the plastics differ, allowing for structured boundaries and integrated light conditioning, along with a light foil that extends along the clear lens, enabling efficient light decoupling and projection functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If weld seams or adhesive seams are used to connect housing components, then the housing can be assembled from separate parts, but the manufacturing cost increases and design flexibility is limited
Solution Approach 1:
The patent combines multiple housing components into a single integrated housing structure produced by injection molding. This eliminates the need for separate weld seams or adhesive connections between parts, thereby reducing manufacturing complexity and cost while maintaining assembly capability through the molding process itself.
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: it provides structural support, integrates mounting features for lighting elements, and incorporates optical surfaces. This multi-functionality reduces the need for additional separate components and their associated joining methods.
2Ease of manufacture
If weld seams are used to connect housing parts, then the housing can be constructed from separate components, but the tolerances of adjacent clearances are affected
Solution Approach 1:
By merging multiple housing components into a single injection-molded piece, the patent eliminates weld seams that would otherwise create tolerance accumulation and clearance issues. The integrated structure ensures consistent dimensional tolerances across all surfaces without the need for post-assembly adjustments.
3Ease of manufacture
If separate housing components are connected with weld seams, then the housing can be assembled, but the integration of lighting functions becomes complicated
Solution Approach 1:
The patent integrates lighting element mounting features directly into the housing structure during injection molding. This allows for seamless integration of lighting functions without requiring separate assembly steps or modifications to connected components, thereby simplifying the overall integration process.
Solution Approach 2:
The housing is designed with pre-formed mounting features, recesses, and attachment points for lighting elements that are created during the injection molding process. This preliminary action eliminates the need for subsequent assembly operations to create these features, simplifying lighting function integration.
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 design simplifies manufacturing, enhances design freedom, and provides high light yield while maintaining mechanical stability and resistance to mechanical stresses, heat, and UV degradation, allowing for cost-effective and efficient production of rear view devices with enhanced functionality.
Implementation Method 1
the refractive index of the plastic of the clear lens is selected to be different from the refractive index of the plastic of the light conductor
Data Source
AI summary
A multifunctional lamp unit includes a side turn indicator including a housing for at least one light conductor with at least one illuminant, and a projection unit. A rearview device including the multifunctional lamp unit, a method of operating the rearview device, and a vehicle including the rearview device are also described.