Automotive Room Lamp Mounting Structure Integration
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Solution Overview
Problem
The conventional automotive room lamp mounting structure is costly and heavy due to the use of a bracket as a reinforcement member, which also complicates the assembly process with adhesive bonding, affecting productivity.
Innovation Solution
The mounting structure eliminates the independent bracket by forming a bracket portion along the outer circumference of the inner housing, which integrates with the ceiling and reinforcement, eliminating the need for adhesive bonding and reducing weight and fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bracket is used as a reinforcement member in the mounting structure, then the strength and stability of the ceiling are improved, but the weight and fabrication cost increase, and the assembly process becomes more complex requiring adhesive bonding
Solution Approach 1:
The patent merges the bracket and ceiling into a single integrated component. The ceiling is designed with a recessed portion that directly receives and secures the lamp assembly, eliminating the need for a separate bracket. This integration maintains structural strength while reducing weight and simplifying the assembly process by removing adhesive bonding steps.
Solution Approach 2:
The ceiling is designed to serve multiple functions: it provides the structural support function previously performed by the bracket, maintains the aesthetic ceiling appearance, and integrates the lamp assembly securing mechanism. The recessed portion of the ceiling acts as both a structural element and a mounting feature, reducing the need for additional components.
2Strength
If a bracket is used as a reinforcement member, then the ceiling strength is improved, but the fabrication cost and device complexity increase
Solution Approach 1:
The patent combines the bracket function with the ceiling structure itself. The ceiling includes a recessed portion that directly accommodates the lamp assembly, eliminating the need for a separate bracket component. This reduces the number of parts and simplifies the overall mounting structure while maintaining the necessary structural support.
Solution Approach 2:
The patent extracts the bracket from the mounting structure and integrates its functionality directly into the ceiling design. By removing the separate bracket component and incorporating the support function into the ceiling's recessed portion, the device complexity is reduced while maintaining structural integrity.
3Reliability
If adhesive bonding is used to fix the bracket to the ceiling, then the bracket is securely attached, but the productivity decreases due to additional assembly steps
Solution Approach 1:
The patent merges the bracket and ceiling into a single component, eliminating the need for adhesive bonding between separate parts. The integrated design allows the lamp assembly to be secured directly through the ceiling's recessed portion using mechanical fastening methods, which are faster and more efficient than adhesive application and curing processes.
Solution Approach 2:
The patent replaces the chemical bonding method (adhesive) with a mechanical fastening system. The ceiling's recessed portion is designed to mechanically secure the lamp assembly, eliminating the need for adhesive application, positioning, and curing time, thereby improving assembly productivity while maintaining reliable attachment.
4Force
If a bracket is used as a reinforcement member, then the structural support is improved, but the weight of the mounting structure increases
Solution Approach 1:
The patent combines the structural support function with the ceiling itself rather than using a separate bracket. The ceiling's recessed portion provides the necessary structural support while being made from the same material as the ceiling, avoiding the addition of extra weight from a separate bracket component.
Solution Approach 2:
The patent uses the same resin material for both the ceiling and the integrated mounting portion, creating a composite structure that maintains structural support capability while minimizing weight. The unified material approach avoids the weight penalty of adding a separate bracket made from different materials.
Data Source
AI summary
A mounting structure including: an outer housing having a first locking portion; a ceiling including a lamp opening portion in a central portion thereof; an inner housing including: a first locking facing portion which is locked in the first locking portion of the outer housing; and a second locking portion on and directly attached to the inner housing; and a reinforcement having a second locking facing portion which is locked on the second locking portion of the inner housing. The ceiling is fixed between the outer housing and the inner housing by locking the first locking facing portion of the inner housing in the first locking portion of the outer housing via the lamp opening portion in the ceiling. A bracket portion shaped so as to follow a shape of an upper side of the ceiling is provided along an outer circumference of the inner housing.