Nylon 4,6 Lamp Socket Reduces Outgassing Fogging

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Lamp sockets used in exterior vehicle lighting applications, made from plastics like Noryl GTX 810, outgas, causing fogging on lens and reflector surfaces, which affects aesthetics and photometric performance, and existing alternatives like PEI are not fully explored for additional materials.

Innovation Solution

A lamp socket assembly using a high-temperature plastic socket body made from nylon 4,6, with a separate housing made from lower-temperature plastics, and a bulb with a sleeve also made from nylon 4,6 or other low-outgassing materials like PEI or PPA, to reduce outgassing and improve thermal and mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If lamp sockets are made from common plastics like Noryl GTX 810, then manufacturing cost and ease of manufacture are improved, but outgassing occurs causing fogging on lens and reflector surfaces

Engineering Contradiction:

Improveease of manufactureVSAvoidoutgassing

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter from common plastics (Noryl GTX 810) to high-temperature resistant plastics (PEI, PPA, nylon 4,6) that maintain structural integrity and resist outgassing at elevated temperatures near light bulbs, thereby eliminating fogging while preserving manufacturing feasibility

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material solutions by specifying plastics with particular thermal and chemical properties (PEI, PPA, nylon 4,6) that combine dimensional stability with low outgassing characteristics, creating a material that satisfies both manufacturing and performance requirements

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If high temperature plastics like PEI are used for lamp sockets, then outgassing is reduced and fogging is minimized, but material cost and manufacturing complexity increase

Engineering Contradiction:

ImproveoutgassingVSAvoidease of manufacture

Core Design Contradiction:

Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The patent applies local quality by specifying that only the socket body portions in direct contact with or nearest to the light source (where temperatures exceed 100°C) be made from high-temperature plastics like PEI or PPA, while other socket components can use conventional plastics, thereby minimizing material cost and manufacturing complexity while still preventing outgassing at critical locations

Inventive Principle:

Principle #3Local quality

3Device complexity

If conventional plastics are used for bulb sleeves and bases, then manufacturing simplicity is maintained, but outgassing produces harmful structures like aniline and benzene

Engineering Contradiction:

Improvedevice complexityVSAvoidoutgassing

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter for bulb sleeves and bases from conventional plastics to high-temperature resistant plastics (PEI, PPA, nylon 4,6) that resist thermal degradation and outgassing, thereby eliminating harmful chemical structures while maintaining manufacturing simplicity through standard molding processes

Inventive Principle:

Principle #35Parameter changes

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

Significantly reduces outgassing, enhances mechanical strength, and maintains dimensional stability, improving the performance and longevity of lamp assemblies by using nylon 4,6 in critical components exposed to high temperatures.

Implementation Method 1

The socket body is made from a high temperature plastic which has a reduced propensity for outgassing, such as nylon 4,6

Methodology Applied

Scientific EffectThermal stability:

Implementation Method 2

nylon 4,6, which has been found to undergo reduced outgassing when compared to at least some of the prior art plastic materials currently used in the industry

Methodology Applied

Scientific EffectOutgassing reduction:

Implementation Method 3

maintains dimensional stability, improving the performance and longevity of lamp assemblies by using nylon 4,6 in critical components exposed to high temperatures

Methodology Applied

Scientific EffectDimensional stability:

Implementation Method 4

enhances mechanical strength, and maintains dimensional stability

Methodology Applied

Scientific EffectMechanical strength enhancement:

Data Source

PatentUS7604386B2Lamp assembly having a socket made from high temperature plastic

Publication Date: 2009.10.20 FEDERAL MOGUL POWERTRAIN INC

AI summary

A lamp socket for an automotive exterior lamp assembly that can be used with a replaceable incandescent bulb. The lamp socket comprises a plastic socket made from nylon 4,6. The lamp socket exhibits reduced outgassing that would otherwise result from photo-oxidative degradation of the polymers in the plastic socket. This helps prevent fogging of the lamp assembly lens and/or reflector for improved performance and aesthetic appearance over the life of the lamp assembly. The incandescent bulb used in the assembly can include a press-sealed end having a sleeve attached over the press-sealed end, and the sleeve can be made from at least one of nylon 4,6, PEI and PPA. The incandescent bulb may also have a molded plastic base, and the base can also be made from at least one of nylon 4,6, PEI and PPA.