Rear-Loading Inner Lens Clips for Vehicle Light Modules

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Solution Overview

Problem

Conventional vehicle light module designs face challenges in hiding exposed fasteners or clips attaching the inner lens to the light frame module, especially in limited packaging spaces, where traditional 'cover up' methods like black-shot molding or secondary bezels are not feasible.

Innovation Solution

The inner lens is designed with a first plurality of U-shaped clips on its lower surface and a second plurality of clips on its upper surface, which engage with corresponding protrusions of the light frame module from the rear side, allowing for secure mounting while keeping the clips and protrusions hidden from the exterior and accommodating compact designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the inner lens is mounted to the light frame module from the front side using conventional clips, then the mounting is secure, but the clips remain exposed to the exterior environment and are visible from the front

Engineering Contradiction:

Improvemounting securityVSAvoidaesthetic appearance

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent inverts the conventional mounting approach by attaching the inner lens to the rear side of the light frame module instead of the front side. The clips are positioned on the rear surface, engaging with protrusions on the interior of the light frame, thereby hiding them from exterior view while maintaining secure mounting.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If cover up methods like black-shot molding or secondary bezels are used to hide the clips, then the clips are concealed, but the packaging space becomes limited and the design becomes more complex

Engineering Contradiction:

Improveclip concealmentVSAvoidpackaging space

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Instead of adding cover-up elements like black-shot molding or secondary bezels, the patent inverts the mounting location to the rear side of the light frame module. This eliminates the need for additional concealing components, maintaining a compact design without compromising clip concealment.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If the clips are made visible or exposed for easy access, then the mounting and maintenance is easier, but the aesthetic appearance is compromised and the design does not meet vibration validation standards

Engineering Contradiction:

Improvemaintenance accessibilityVSAvoidaesthetic appearance

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent relocates the clips to the rear side of the light frame module, where they remain concealed from exterior view during normal operation. The clips are designed to engage with protrusions on the interior surface, providing both aesthetic concealment and secure mounting that meets vibration validation standards.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The clips are extracted from the visible front surface and repositioned to the hidden rear surface of the light frame module. This separation of the fastening function from the visible aesthetic surface allows the front to remain clean and attractive while the rear handles the mechanical attachment function.

Inventive Principle:

Principle #2Taking out (Extraction)

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 configuration ensures that the fastening components are not visible from the exterior, fits within limited packaging spaces, and meets vibration validation standards, providing a secure and aesthetically pleasing lighting module solution.

Implementation Method 1

each of the first plurality of clips has a U-shaped extended end with a hollow central region configured to receive a respective first protrusion of the first plurality of protrusions of the light frame module. the U-shaped extended end of said each of the first plurality of clips is configured to bend and lock the first protrusion into place

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a first plurality of clips positioned on a lower surface of the inner lens configured to engage with a corresponding first plurality of protrusions of a light frame module; and a second plurality of clips positioned on an upper surface of the inner lens configured to engage with a corresponding second plurality of protrusions of the light frame module

Methodology Applied

Scientific EffectMechanical Fastener: Mechanical Fastener

Data Source

PatentUS10323815B2Rear-loading clip for a light module

Publication Date: 2019.06.18 VALEO NORTH AMERICA INC(US)

AI summary

An inner lens for a light module includes a first plurality of clips positioned on a lower surface of the inner lens configured to engage with a corresponding first plurality of protrusions of a light frame module; and a second plurality of clips positioned on an upper surface of the inner lens configured to engage with a corresponding second plurality of protrusions of the light frame module. The inner lens is configured to be mounted to the light frame module from a rear side of the light frame module.