Resin-Sealed Vehicle Body Lighting for Gap-Free Optical Integration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing motor vehicle body part designs with integrated light elements face challenges in adaptability due to the need for rigid supports, which are difficult to fit into various housing types and often highlight assembly clearances and outcrops, compromising visual quality, especially for large optical elements.

Innovation Solution

A motor vehicle body part with an optical element featuring a flexible light source supported by a fixed element on the internal face, sealed with resin injected into an opening, allowing for flexible assembly and seamless integration without visible attachment points, using materials like polypropylene, silicone, and polyurethane, ensuring homogeneous light transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid support is used to house the light source, then the light source can be securely fixed, but it becomes difficult to adapt to various housing types and highlights assembly clearances

Engineering Contradiction:

Improvesecure fixation of light sourceVSAvoidadaptability to housing types

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent uses a flexible membrane made of elastomeric material to replace rigid support structures. This membrane can conform to various housing shapes and sizes, eliminating the need for precise rigid fittings while maintaining secure fixation of the light source. The flexibility allows adaptation to different body part geometries without highlighting assembly clearances.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical state of the support structure from rigid to flexible by using elastomeric materials. This parameter change allows the support to adapt its shape and conform to different housing types while maintaining structural integrity and secure fixation of the light source.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If attachment points are used to fix the optical element, then the element can be securely mounted, but the attachment points become visible and disturb light homogeneity

Engineering Contradiction:

Improvesecure mounting of optical elementVSAvoidhomogeneity of light

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The flexible membrane extends to cover the entire opening and can be used to secure the optical element without visible attachment points. The membrane's flexibility allows it to conform to the optical element while maintaining a seamless appearance that does not disturb light homogeneity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent merges the mounting function with the sealing membrane itself. The membrane serves both as a seal and as the mounting structure for the optical element, eliminating separate attachment points that would be visible and disrupt light homogeneity.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If a long slot is created in the body part to accommodate a large optical element, then the element can be installed, but the slot tends to open due to wall flexibility, accentuating clearances

Engineering Contradiction:

Improveaccommodation of large optical elementVSAvoidclosure of slot

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The flexible membrane is used to close the slot opening while accommodating the optical element. The membrane's elasticity allows it to conform to the slot geometry and maintain closure despite wall flexibility, preventing the slot from opening and accentuating clearances.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible membrane acts as an intermediary between the slot opening and the external environment. It provides a seamless closure that accommodates the optical element while preventing the slot from opening, maintaining both aesthetics and functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enables easy adaptation to complex shapes and large body parts, maintaining visual quality by eliminating clearances and outcrops while ensuring reliable sealing and light transmission, even in large and slender slots.

Implementation Method 1

the resin is transparent or translucent; the optical element comprises at least one light element capable of transmitting light from the internal face to the external face of the wall through the resin

Methodology Applied

Scientific EffectLight transmission: Refraction

Implementation Method 2

the sealing and protection being ensured by a resin injected or poured into the opening

Methodology Applied

Scientific EffectSealing: Physical Containment

Data Source

PatentEP3981647B1Vehicle body part comprising a lighting device covered by a transparent resin

Publication Date: 2024.01.10 OPMOBILITY SE

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

The invention relates to a part (10) of the bodywork of a motor vehicle (120), comprising a wall (20) having an external face (30), an internal face (40), and at least one opening (50), characterized in that the part (10) comprises an optical element (60) fixed on the internal face (40) opposite (along) the opening (50), the opening (50) being filled by a transparent or translucent resin (100) so as to ensure a seal between the external face (30) and the optical element (60).