Optical Assembly Mounting Structure for Vehicle Lamps

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Solution Overview

Problem

Existing optical assembly mounting structures for miniaturized vehicle lamps lack the necessary accuracy, reliability, and simplicity to meet the demands of modern vehicle lamp design, which requires compact components and precise optical component positioning.

Innovation Solution

The proposed optical assembly mounting structure includes a primary optical element, a lens mount, a circuit board, and a radiator, with specific mounting portions, limiting frames, C-shaped limiting structures, and positioning grooves that ensure accurate and stable positioning of the optical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the vehicle lamp is miniaturized with compact component arrangement, then the size of the lighting device is reduced, but the positioning accuracy of optical components deteriorates

Engineering Contradiction:

Improvesize of lighting deviceVSAvoidpositioning accuracy of optical components

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The mounting structure is divided into multiple functional components: lens mount for holding the lens, circuit board for electronic components, radiator for heat dissipation, and primary optical element holder. Each component has dedicated positioning features (limiting frames, positioning grooves, fitting portions) that ensure accurate relative positioning while allowing the overall device to be compact.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lens mount and circuit board act as intermediary components that mediate between the various optical elements and the housing. These intermediaries provide standardized mounting interfaces with precise positioning features, enabling accurate component placement without requiring the entire device to be large.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If the mounting structure is simplified for miniaturization, then the device complexity is reduced, but the reliability of optical assembly positioning deteriorates

Engineering Contradiction:

Improvestructure complexityVSAvoidpositioning reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Multiple functions are merged into single components: the lens mount simultaneously holds the lens, provides positioning references for the circuit board, and interfaces with the housing. The circuit board integrates electronic components, positioning features, and thermal management interfaces. This merging reduces the number of separate parts while maintaining positioning reliability through carefully designed integrated features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The radiator serves multiple functions: heat dissipation for the LED, structural support for the optical assembly, and positioning reference through its C-shaped limiting structures. The circuit board provides both electrical connectivity and mechanical positioning. This multi-functionality reduces overall complexity while ensuring reliable positioning.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of moving object

If the component arrangement is compacted for miniaturization, then the volume is reduced, but the heat dissipation efficiency deteriorates

Engineering Contradiction:

Improvevolume of lighting deviceVSAvoidheat dissipation efficiency

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The optical components and circuit board are nested within the housing structure, with the radiator integrated into the mounting structure. The C-shaped limiting structures on the radiator are nested with corresponding positioning grooves on the circuit board, creating a compact nested arrangement that maintains thermal pathways while minimizing overall volume.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The radiator acts as an intermediary thermal management component that is integrated into the mechanical mounting structure. It provides thermal pathways from the LED to the housing while simultaneously serving as a positioning reference, enabling compact design without sacrificing heat dissipation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12209727B2Optical assembly mounting structure, vehicle lamp lighting device, vehicle lamp, and vehicle

Publication Date: 2025.01.28 HASCO VISION TECHNOLOGY CO LTD

AI summary

An optical assembly mounting structure comprising a primary optical element, a lens mount, a circuit board, and a radiator. Mounting portions on two sides of the primary optical element; each mounting portion comprising a front fitting portion and a rear fitting portion; a primary element limiting frame on the lens mount; the radiator has two C-shaped limiting structures opposite to each other; the circuit board has two C-shaped positioning grooves; the circuit board mounted on the radiator via a fitting between the C-shaped positioning grooves and the C-shaped limiting structures; rear ends of the primary optical element mounted on the radiator via a fitting between the rear fitting portions and the C-shaped limiting structures; front ends are mounted on the lens mount via the fitting between the front fitting portions and the primary element limiting frame. Also, a lighting device comprising the mounting structure, a vehicle lamp, and a vehicle.