Vehicle Overhead Console Frustum Reflector Light Distribution
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Solution Overview
Problem
Current vehicle lamp assemblies are costly to manufacture and inefficient in directing light to desired locations within the vehicle compartment.
Innovation Solution
A vehicle overhead console design featuring a housing with a substrate defining a cavity, a light source surrounded by a frustum reflector, and a trim member with varying thickness, along with an offset second lens, which directs light efficiently and aesthetically while being cost-effective to produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional lamp assemblies are used, then lighting function is provided, but manufacturing cost is high
Solution Approach 1:
The reflector is integrated with the housing as a single component rather than separate parts, reducing assembly steps and manufacturing cost while maintaining the lighting function. The frustum-shaped reflector is formed as part of the housing structure, eliminating the need for separate reflector installation.
Solution Approach 2:
The housing serves multiple functions: it provides structural support, acts as a mounting structure for the light source, and functions as a reflector through its frustum-shaped interior surface. This multi-functionality reduces the number of components needed and lowers manufacturing cost.
2Productivity
If conventional lamp assemblies are used, then lighting is provided, but light distribution efficiency is poor
Solution Approach 1:
The reflector is designed with a frustum-shaped curved interior surface that efficiently directs light rays from the light source toward the target area. The curved geometry optimizes light reflection and distribution, improving light energy utilization and reducing waste.
Solution Approach 2:
The reflector's interior surface has specific reflective properties concentrated in the frustum region to optimize light direction. The varying thickness of the trim member also creates local optical effects to enhance light distribution in specific areas while maintaining efficiency.
3Ease of manufacture
If a frustum reflector with offset lens and varied thickness trim member is used, then light distribution is enhanced and cost is reduced, but structural complexity increases
Solution Approach 1:
Multiple components (reflector, housing, trim member) are integrated into unified structures. The frustum reflector is formed as part of the housing, and the trim member is integrated with the lens assembly, reducing the total number of separate parts despite the enhanced functionality.
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 provides efficient illumination in the vehicle compartment by integrating a reflector with the overhead console, reducing manufacturing costs and enhancing light distribution, while maintaining a stylish appearance.
Implementation Method 1
A reflector has a first end portion that surrounds the light source and a second end portion proximate a first lens
Data Source
AI summary
A vehicle overhead console is provided herein. The vehicle overhead console includes a housing and a substrate defining a cavity therebetween. A light source is within the cavity. A reflector has a first end portion that surrounds the light source and a second end portion proximate a first lens. A trim member has a thickness that varies laterally. A second lens is offset from the first lens.