Overmolded Light Guide for Homogeneous Rear-View Lamp Emission
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Solution Overview
Problem
Existing lighting devices for rear-view mirrors in vehicles face challenges in achieving homogeneous light emission and are often complex and costly to install due to multiple components and potential misalignment during assembly.
Innovation Solution
The light guide and housing/lens are connected through overmolding in specific areas, forming a single unit with a form-fitting and chemically bonded connection, allowing for different materials and optical properties, and simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components (light guide, housing, lens) are used, then assembly flexibility is improved, but assembly complexity and installation cost increase
Solution Approach 1:
The patent merges the light guide, housing, and lens into a single integrated component produced through overmolding. The light guide is first molded, then the housing material is molded over it, and finally the lens is molded over the housing, creating an inseparable unit that eliminates assembly steps while maintaining design flexibility
Solution Approach 2:
The patent applies nested doll principle by molding components in layers: the housing is molded over the light guide, and the lens is molded over the housing. This nested structure allows multiple functional elements to be integrated into a single component without requiring separate assembly operations
2Adaptability or versatility
If multiple separate components are used, then functional optimization is improved, but positioning precision and light homogeneity deteriorate
Solution Approach 1:
By combining light guide, housing, and lens into one overmolded component, the patent eliminates relative displacement between parts. The inseparable connection ensures precise positioning is maintained throughout the product lifecycle, while each component's function is optimized through the molding process parameters
3Strength
If adhesive bonding or welding is used to connect components, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The overmolding process merges multiple components into a single piece with inseparable connections. This eliminates the need for adhesive bonding or welding operations, reducing manufacturing complexity while maintaining or improving structural integrity through the integrated molding process
Solution Approach 2:
The patent uses composite materials principle by molding different materials (light guide material, housing material, lens material) in layers to create an integrated component. The overmolding process creates strong bonds between different materials without requiring separate joining operations
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 approach ensures high homogeneity of light emission, reduces installation complexity, and lowers costs by integrating components into a single, inseparable unit with enhanced optical variability.
Implementation Method 1
light produced by at least one light source can be coupled into the light guide device
Implementation Method 2
connected through overmolding in specific areas, forming a single unit with a form-fitting and chemically bonded connection
Data Source
AI summary
A lighting device for a rear-viewing device of a motor vehicle includes at least one housing device, at least one lens, and at least one light guide device arranged at least in certain areas between the housing device and the lens. Light produced from at least one light source can be coupled into the light guide device, and the light guide device on the one hand and the housing device and/or the lens on the other hand are at least in certain areas connected to one another by means of overmolding, at least in certain areas, the light guide device. A method for producing such a lighting device is also described.