Stepped Optical Module Assembly for Vehicle Lighting
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Solution Overview
Problem
Existing motor vehicle lighting or signaling devices face challenges in manufacturing complex shapes and easy assembly, particularly in integrating optical modules with specific functionalities like Daytime Running Lights and position lights, while maintaining cost-effectiveness.
Innovation Solution
The design incorporates a housing with a printed circuit board and separate rear and front optical assemblies, featuring a Fresnel collimator and stepped transverse lighting surfaces, respectively, with positioning and fixing mechanisms using axes and rivets for precise assembly without screws, allowing for easy manufacturing and assembly of optical modules with complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If separate rear and front optical assemblies are used with stepped transverse lighting surfaces, then the optical performance and design flexibility are improved, but the device complexity increases
Solution Approach 1:
The optical module is divided into separate rear and front optical assemblies, each with specific functions. The rear assembly handles light collection and initial direction, while the front assembly with stepped transverse lighting surfaces provides the final light distribution pattern. This segmentation allows optimization of each assembly independently while achieving complex optical performance.
Solution Approach 2:
The front optical assembly incorporates stepped transverse lighting surfaces that extend in the longitudinal direction, adding a dimensional aspect to the light distribution. This creates multiple lighting levels and enhances the optical performance by providing varied illumination patterns in different spatial dimensions.
2Manufacturing precision
If positioning means with at least two axes and fixing means with rivets are used, then the manufacturing precision and assembly accuracy are improved, but the ease of manufacture decreases
Solution Approach 1:
The housing is pre-equipped with positioning axes and fixing means (rivets) before the optical module assembly is installed. The positioning axes extend from the bottom of the housing towards the front, establishing reference lines that guide the precise placement of the optical assemblies. This preliminary preparation ensures high assembly accuracy without requiring complex adjustment mechanisms during installation.
Solution Approach 2:
The optical assemblies incorporate self-positioning features such as protrusions that cooperate with orifices and printed circuit board clearances. These features automatically align the components during assembly, reducing the need for precision machining and manual adjustment, thereby improving assembly accuracy while maintaining ease of manufacture.
3Stability of the object's composition
If the front optical assembly is fixed in direct contact with the rear optical assembly, then the structural stability is improved, but the ease of assembly decreases
Solution Approach 1:
The rear and front optical assemblies are fixed in direct contact with each other, merging their structural functions. This direct contact eliminates gaps and misalignments between the assemblies, ensuring stable optical paths and consistent light distribution. The merged structure provides rigidity and reliability while maintaining a compact design.
Solution Approach 2:
Positioning means such as protrusions and orifices act as intermediaries between the rear and front optical assemblies. These features facilitate the direct contact fixation by providing precise alignment references and mechanical connection points, making the assembly process straightforward despite the direct contact requirement.
4Reliability
If protrusions cooperating with orifices and printed circuit board clearances are used for securing, then the reliability of the optical module is improved, but the device complexity increases
Solution Approach 1:
The optical module incorporates self-positioning and self-fixing features where protrusions on one component automatically cooperate with orifices and clearances on adjacent components. This self-service mechanism ensures reliable connection without requiring additional fastening operations or complex adjustment procedures, enhancing reliability while maintaining simplicity.
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 the cost-effective production of motor vehicle lighting or signaling devices with complex optical module designs, ensuring easy assembly and precise positioning, thus enhancing the optical performance and durability while reducing production costs.
Implementation Method 1
a rear optical assembly comprising at least one collimator, in particular a Fresnel type collimator
Data Source
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AI summary
The invention relates to an optical module (100), in particular for a lighting or signaling device (10) of a motor vehicle (1), the optical module comprising a printed circuit board (110) equipped with at least one light source (111), in particular a light source of the light-emitting diode type, and a rear optical assembly (120) comprising at least one collimator (121), in particular a Fresnel-type collimator (121), arranged opposite the at least one light source (111), characterized in that the optical module (100) comprises a front optical assembly (130), separate from the rear optical assembly (120), having a front face (131) comprising at least two transverse lighting surfaces (132) arranged at different levels in the longitudinal direction to form at least two steps of an overall stepped shape, the front optical assembly (130) being fixed in direct contact with the rear optical assembly (120).