Instrument Panel Telltale Light Leakage Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Instrument clusters in vehicles face issues with light leakage, increased number of fasteners required for assembly, and vibrations leading to buzz, squeak, and rattle, which affect aesthetics and operator satisfaction.
Innovation Solution
The solution involves optimizing the attachment scheme with a reduced number of fasteners, specifically using 4 fasteners to secure the components, and incorporating light blocking features in the telltale light chimneys to minimize light leakage, while employing pulse width modulation to adjust LED currents for optimal illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly methods with multiple fasteners are used to secure instrument cluster components, then assembly strength and reliability are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent combines multiple separate components (light housing, appliqué, visor) into an integrated assembly where the light housing serves multiple functions: it contains LEDs, provides structural support, and integrates light-blocking features. This merging eliminates the need for multiple separate fasteners to secure different components, reducing fastener count while maintaining assembly reliability through the unified structure.
2Object-affected harmful factors
If light blocking features are added to telltale light chimneys to prevent light leakage, then aesthetics and telltale visibility are improved, but device complexity increases
Solution Approach 1:
The patent applies light-blocking features specifically at the critical locations where light leakage occurs (at the interfaces between light housing and appliqué, and at telltale light chimney openings) rather than throughout the entire structure. This localized application of light-blocking material or structural features effectively prevents light leakage while minimizing the addition of overall device complexity.
3Object-affected harmful factors
If warpage control and part mismatch prevention are implemented to reduce light leakage, then light leakage is reduced, but manufacturing precision requirements and cost increase
Solution Approach 1:
The patent incorporates light-blocking features during the manufacturing process itself, rather than requiring post-assembly adjustments or extremely tight tolerances. By pre-integrating light-blocking material or structures into the light housing and appliqué design, the system compensates for normal warpage and part mismatch that occur during curing and assembly, effectively preventing light leakage without requiring excessive manufacturing precision.
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 approach effectively reduces light leakage to imperceptible levels, minimizes the number of fasteners needed, and eliminates buzz, squeak, and rattle issues, ensuring improved aesthetics and functionality of the instrument cluster.
Implementation Method 1
incorporating light blocking features in the telltale light chimneys to minimize light leakage
Implementation Method 2
employing pulse width modulation to adjust LED currents for optimal illumination
Data Source
AI summary
The disclosure relates to an improved instrument panel design with reduced buzz, squeak and rattle as well as reduced light leakage to instrument panel telltales.