Rearview Blinker Module Coating and Housing for Split Light Regions
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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 various 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, where a first coating element acts as a reflector layer to prevent light loss and a second coating element serves as a cover to interact with the housing, allowing for flexible design and simplified assembly, including the use of inserts for additional design features like logos or emblems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate illuminant units are used to fulfill design and legal illumination tasks, then the lighting functions are well separated and reliable, but the device complexity and manufacturing cost increase
Solution Approach 1:
The single illuminant unit is segmented into two spatially separated light regions through the housing structure. The housing forms an opaque section that divides the light path, creating a first light region for design purposes and a second light region for legal illumination requirements, while using only one illuminant unit
Solution Approach 2:
The single illuminant unit serves multiple functions simultaneously - it provides both the design lighting (first light region) and the legally required illumination (second light region). The housing structure enables this multi-functionality by creating an opaque section that directs light to different regions
2Shape
If the housing forms an opaque section to separate light 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 housing structure incorporates specific local features such as recesses and protrusions that enable different design configurations. These local structural variations allow the same basic housing design to be adapted for different series and manufacturer emblems while maintaining the light region separation function
Solution Approach 2:
The design system allows for dynamic adaptation through modular components. The housing can be configured with different opaque section designs for different series, enabling design flexibility and versatility while maintaining the core function of separating light regions
3Reliability
If complex assembly processes are used to meet design requirements and legal standards, then the illumination and design requirements are satisfied, but the assembly time and production efficiency decrease
Solution Approach 1:
The housing structure integrates multiple functions into a single component. The opaque section that separates light regions is formed as an integral part of the housing, eliminating the need for separate assembly steps to install light separators. This merging of functions reduces assembly complexity and cycle time while maintaining compliance with design and legal illumination standards
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 production of blinker modules that are easy to manufacture, cost-effective, and offer high design flexibility, with improved light distribution and simplified installation, allowing for a variety of designs to be achieved with a single housing shape, reducing production costs and enabling efficient assembly even for smaller series.
Implementation Method 1
a first coating element is designed as a reflector layer and is arranged on at least one first surface region of the light disk
Implementation Method 2
the illuminant unit is designed to couple light emitted by the illuminant into the lighting element
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.