Automotive Taillight Optics Integration for Easier Assembly
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Solution Overview
Problem
Existing automotive taillights with high-power LEDs are complicated to assemble due to the precise alignment requirements of reflector bodies, corrective optics, and shielding masks, leading to high production costs.
Innovation Solution
The reflector body and corrective optics are integrated into a single, monolithic concave moulded piece made of transparent plastic, eliminating the need for precise alignment and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate reflector body and corrective optics are used, then light control precision is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the reflector body and corrective optics into a single integrated optical component. The reflector body with its reflective surface and the corrective optics with its light-distributing surface are formed as one piece, eliminating the need for separate assembly and alignment of these two components while maintaining their respective light control functions.
Solution Approach 2:
The integrated optical component is segmented into distinct functional surfaces: a reflective surface for directing light and a light-distributing surface for correcting and uniformizing light distribution. This segmentation of functions within a unified structure allows the component to perform multiple optical functions simultaneously without requiring separate parts.
2Manufacturing precision
If precise alignment of multiple components is required, then optical performance is improved, but production cost increases
Solution Approach 1:
By combining the reflector body and corrective optics into one integrated component, the patent eliminates the need for precise alignment procedures between separate parts. The single-component design inherently maintains optimal optical relationships without requiring complex alignment fixtures, adjustment mechanisms, or skilled manual assembly, thereby reducing production costs.
3Adaptability or versatility
If multiple separate components are used, then functional flexibility is improved, but assembly time increases
Solution Approach 1:
The integration of reflector body and corrective optics into a single component dramatically reduces assembly time by eliminating multiple assembly steps, fasteners, and alignment procedures. The unified component can be installed as one piece, streamlining the assembly process while maintaining all necessary optical functions through its multi-surface design.
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 integration reduces assembly complexity and costs by allowing easier handling and reduced use of centring pins, resulting in a faster and simpler assembly process.
Implementation Method 1
provided with a concave reflecting portion (5a) with a roughly semi-parabolic profile, which is oriented so as to reflect the incident light towards the facing transparent or semi-transparent sector of the front half-shell (3)
Implementation Method 2
an electrically-powered light source, which emits light on command and is arranged inside the rear body (2), at the side of the concave moulded piece (5) and preferably also close to the bottom of rear body (2), so as to direct the light produced towards the concave reflecting portion (5a)
Data Source
Figure 1~3
Figure 2
Figure 4~5
AI summary
Automotive light (1) comprising: a rear body (2) adapted to be fixed on the vehicle; a front half-shell (3) arranged to close the mouth of said rear body (2); and at least one lighting assembly (4), which is placed inside the rear body (2), is adapted to back light a corresponding transparent or semi-transparent sector of the front half-shell (3) and in turn comprises: a reflector body (5a) provided with a reflective surface adapted to reflect and direct the light towards the corresponding transparent or semi-transparent sector of the front half-shell (3); a light source (6) adapted to emit and direct the emitted light towards said reflective surface; and a corrective optics (5b) that is placed between the reflector body (5a) and the front half-shell (3), so as to be crossed by the light (r) reflected by the reflector body (5a) towards the front half-shell (3), and is structured so as to direct and/or distribute and/or filter and/or diffuse in a predetermined manner the light (r) directed towards the front half-shell (3); the reflector body (5a) and the corrective optics (5b) being made in a single piece and of transparent plastic material.