Primary Lens Holder for Motor Vehicle Lighting Precision
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Solution Overview
Problem
The existing primary optics assemblies for motor vehicle lighting devices are complex, require large space, and have complicated assembly processes, making precise and automated positioning of primary optics elements challenging and costly.
Innovation Solution
The use of a holder with tension spring elements and a metal mount, made via thixomolding, to precisely position and fix primary optics elements made of dimensionally stable but elastically deformable materials like silicone, allowing for automated assembly and electrical connection, with the tension spring element clamping the primary optics array and providing stability at distal ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual primary optics elements are held by separate holding brackets with fastening sections, then the optical properties are preserved, but the structure becomes complicated and space requirements increase
Solution Approach 1:
The patent combines multiple separate holding brackets into a single integrated holder that accommodates multiple primary optics elements. The holder features a matrix arrangement of positioning openings that directly receive and secure the optics elements without requiring separate fastening sections, thereby simplifying the overall structure while maintaining optical integrity.
Solution Approach 2:
The holder serves multiple functions simultaneously: it positions, supports, and secures multiple primary optics elements in a matrix arrangement. The single holder structure replaces multiple individual holding brackets, providing a universal mounting solution that reduces structural complexity and space requirements.
2Reliability
If holding brackets exert locally limited force on primary optics elements, then optical properties are maintained, but assembly complexity increases
Solution Approach 1:
The patent integrates the positioning and securing functions into a single holder structure with multiple positioning openings, eliminating the need for separate holding brackets. This unified approach simplifies the assembly process while maintaining the localized force application needed to preserve optical properties.
3Manufacturing precision
If positioning openings are shaped exactly like outer peripheral surfaces, then precise positioning is achieved, but manufacturing complexity increases
Solution Approach 1:
The holder features positioning openings with specific local geometries that match the outer peripheral surfaces of the corresponding primary optics elements. Each opening is tailored to its specific element's shape, enabling precise positioning through direct geometric matching without requiring complex overall holder structures.
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
Enables precise positioning and fixing of primary optics elements with an accuracy of around 0.06 mm, simplifying the assembly process, reducing costs, and allowing for automated robotic assembly while maintaining optical stability and functionality.
Implementation Method 1
The mount has a tension spring element which fixes the primary optics elements relative to the mount when the primary optics elements are completely inserted into the mount
Implementation Method 2
The use of a holder with tension spring elements and a metal mount, made via thixomolding
Data Source
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AI summary
The invention relates to a primary optics assembly (10) for use in a lighting device (1) of a motor vehicle, comprising several elongated primary optics elements (12) arranged side by side and/or one above the other, each having a proximal end (13) and a distal end (15) and a cross-section that increases from the proximal end (13) to the distal end (15). It is proposed that the primary optics elements (12) be made of a dimensionally stable but elastically deformable, transparent material and be positioned and attached to a light source (100) or a light source carrier (104) of the lighting device (1) by means of a holder (20), wherein the holder (20) has retaining elements (22) for highly precise positioning of the primary optics elements (12) in the region of their proximal ends (13).