Star-Shaped Car Light Lens Module for Fast Adhesive-Free Assembly
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Solution Overview
Problem
Conventional car lights require time-consuming assembly due to adhesive use, limit shape options to circular or elliptical lenses, and are difficult to maintain or recycle.
Innovation Solution
A lens module design featuring a lens with a four-pointed star shape and engaging grooves, coupled with a rear and front cover, allows for tool-free assembly and easier maintenance, using a frame to secure components without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to fix components together, then the assembly is secure and stable, but the assembly time increases significantly and maintenance becomes difficult
Solution Approach 1:
The patent replaces the chemical bonding system (adhesive) with a mechanical fastening system (screws). The base seat is equipped with threaded holes that receive screws, allowing components to be securely fixed through mechanical threads rather than chemical adhesion. This substitution eliminates drying time while maintaining secure assembly, and enables easy disassembly for maintenance by simply removing the screws.
2Ease of manufacture
If conventional circular or elliptical lenses are used, then the design is simple and symmetrical, but the shape options are limited and consumer choice is reduced
Solution Approach 1:
The patent applies asymmetry by designing the lens with a four-pointed star shape instead of traditional circular or elliptical forms. The lens includes four protruding segments extending from a central region, creating an asymmetric geometric pattern. This asymmetric design provides diverse shape options for consumer preference while maintaining manufacturability through standard lens fabrication processes, thus resolving the contradiction between design simplicity and shape versatility.
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
Facilitates faster assembly, enhances illumination uniformity, and provides shape diversity beyond traditional circular or elliptical lenses, improving maintenance and recyclability.
Implementation Method 1
the shape and curvature of the lens are carefully designed to adhere to the regulations... as such, the shape and curvature of the lens are carefully designed to adhere to the regulations
Data Source
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AI summary
A lens module (1) includes a lens (11) having a front portion (111) and a rear lens portion (112) that has four notches (102), a rear cover (12), and a front cover (13) retaining the lens (11) therein and coupled to the rear cover (12). The front lens portion (111) has four vertices (113) projecting away from an optical axis (A), such that the front lens portion (111) has a four-pointed star shape. The rear cover (12) is connected to the lens (11), and has a base portion (121), and two protruding wall portions (122) defining a mounting hole (105) that corresponds in shape to the lens (11). The lens (11) is fittingly mounted in the mounting hole (105). Each of the protruding wall portions (122) has two recessed portions (123). Each of the notches (102) is engaged with a respective one of the recessed portions (123).