Rearview Blinker Module Assembly With Reflective Light Guide
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Solution Overview
Problem
Existing blinker modules for rearview devices lack design flexibility and cost-effectiveness, particularly in terms of shape and color, and require complex assembly processes to meet varying design requirements and legal illumination standards.
Innovation Solution
A method for manufacturing a blinker module using a lighting element with a light guide and a light disk, combined with a first coating element as a reflector layer and a second coating element as a cover, allowing for adaptable design features such as logos or emblems, and formed through injection molding for cost-effective and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two separate illuminant units are used to fulfill design and legal illumination tasks, then the lighting functions are achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The single illuminant unit is segmented into two spatially separated light regions by an opaque section (cover) within the housing. This allows one illuminant to fulfill both design and legal illumination functions simultaneously, reducing the number of components while maintaining functional versatility
Solution Approach 2:
A single illuminant unit is designed to serve multiple purposes: providing both the design lighting region and the legal illumination region. The opaque section within the housing enables this multi-functionality by directing light from one illuminant to create two distinct visual effects
2Device complexity
If the housing forms an opaque section between recesses for two lighting regions, then the single illuminant unit appears divided into two parts, but the design flexibility for different series and manufacturer emblems is limited
Solution Approach 1:
The opaque section is designed as a separate, replaceable component with specific local properties (transparency, color, emblem integration) that can be varied for different series while maintaining the same overall housing structure. This allows manufacturer emblems and different design requirements to be accommodated by changing only the opaque section
Solution Approach 2:
The opaque section is pre-designed and pre-assembled within the housing before final module assembly. This preliminary preparation enables easy replacement and adaptation for different series without requiring complex reconfiguration of the entire module
3Ease of manufacture
If traditional blinker module assembly processes are used, then the modules can be assembled, but the assembly time and cycle times are excessive
Solution Approach 1:
Multiple components (illuminant unit, opaque section, housing elements) are merged into a more integrated assembly structure that reduces the number of separate assembly steps. The pre-assembled opaque section within the housing allows for faster integration into the final module
Solution Approach 2:
Components are pre-assembled and pre-positioned during manufacturing to facilitate rapid final assembly. The opaque section is already integrated within the housing structure, eliminating the need for complex alignment and attachment operations during module assembly
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 method enables the creation of blinker modules that are easy to manufacture and assemble, offering flexible design options while maintaining high-quality illumination, reducing light loss, and simplifying installation by integrating design elements directly into the module rather than the housing, thus reducing production costs and enabling efficient production even for smaller series.
Implementation Method 1
a first coating element (17), in particular in the form of a reflector layer, is arranged on a first surface region (15) of the light disk
Implementation Method 2
a light guide, the light emitted by the illuminant being transmitted into the light guide
Data Source
AI summary
A method for manufacturing a blinker module for a rearview device of a motor vehicle includes the steps of providing at least one lighting element comprising at least one light guide and at least one light disk or lens and providing of at least one illuminant unit comprising at least one illuminant, wherein the illuminant unit is designed to couple light emitted by the illuminant into the lighting element. A blinker module, rearview device and motor vehicle, including the blinker module manufactured according to the method, are also described.