Rear Light Mounting Structure for Stamping and Welding Constraints
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Solution Overview
Problem
Existing taillight mounting structures face challenges in maximizing luminous area while maintaining structural integrity and manufacturing efficiency, due to issues such as reduced flange angles leading to difficult welding, negative angles in stamping, and increased cracking.
Innovation Solution
A side wall taillight mounting structure comprising a three-part assembly of a taillight mounting connecting plate, upper, and lower taillight mounting plates, with overlapping edges and gaps for adjustment, and using cold arc welding where spot welding is not feasible, along with a flange structure for improved welding surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a rear light is mounted on a side panel of an automobile, then the design flexibility and aesthetic appeal are improved, but the risk of collision damage increases due to the protruding structure
Solution Approach 1:
The rear light assembly is nested within a recess formed in the side panel, with the rear light housing fitting into the recess space. This nesting arrangement allows the rear light to be mounted on the side panel while maintaining a flush or recessed profile, improving design flexibility while reducing collision damage risk by eliminating protruding structures.
Solution Approach 2:
The side panel is segmented to form a recess that accommodates the rear light housing. The mounting structure divides the side panel into different zones: a recessed area for the rear light and a surrounding area for the panel body. This segmentation enables the rear light to be integrated into the side panel design without creating external protrusions, thus maintaining aesthetic appeal while reducing collision vulnerability.
2Shape
If a rear light is mounted on a side panel, then aesthetic appeal and design variety are improved, but manufacturing complexity increases due to additional mounting structures
Solution Approach 1:
The mounting structure merges the rear light housing with the side panel recess, creating an integrated assembly where the housing is directly received and secured within the recess. The mounting bracket combines multiple functions: structural support, positioning, and securing mechanisms. This merging reduces the number of separate components and simplifies the overall manufacturing process while maintaining aesthetic appeal.
Solution Approach 2:
The mounting bracket is designed as a multi-functional component that performs several functions simultaneously: providing structural support for the rear light, positioning the housing within the recess, securing the assembly through fastening mechanisms, and enabling adjustment or removal. This universal design reduces the need for multiple specialized parts, simplifying manufacturing while achieving the desired aesthetic appearance.
3Shape
If a rear light is mounted on a side panel, then design flexibility is improved, but repairability worsens due to integrated mounting structures
Solution Approach 1:
The mounting structure is segmented into separable components: the mounting bracket, the rear light housing, and the fastening elements. This segmentation allows the rear light assembly to be independently removed from the side panel recess without damaging the mounting structure or the panel itself. The modular design maintains aesthetic appeal when installed but facilitates easy repair and replacement by allowing discrete component removal and reinstallation.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A side panel rear light mounting structure, comprising a side panel outer plate (1) and a rear light mounting plate assembly (2). The side panel outer plate (1) is welded to the rear light mounting plate assembly (2); the rear light mounting plate assembly (2) comprises a rear light mounting connecting plate (21), an upper rear light mounting plate (22), and a lower rear light mounting plate (23); the lower rear light mounting plate (23) comprises a first welding edge (231) and a second welding edge (232); the first welding edge (231) and the second welding edge (232) are adjacent to each other; the rear light mounting connecting plate (21) is welded to the first welding edge (231); the upper rear light mounting plate (22) is welded to the second welding edge (232); and the rear light mounting connecting plate (21) and the upper rear light mounting plate (22) are separately welded to the side panel outer plate (1). Also disclosed are a side panel rear light mounting method, an automobile rear light, and an automobile. By splitting traditional rear light mounting plates into smaller parts, the part accuracy is improved, thereby solving the problems of difficulty in forming and cracking of rear lights in the prior art caused by a negative angle in the stamping direction of rear light mounting plates during maximizing light-emitting areas.