Universal Thermal-Expansion Compensator for Headlamp Light Modules
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Solution Overview
Problem
Existing thermal-expansion compensators for headlamp units are specific to each vehicle model, requiring complex design and high development costs due to the need for precise geometric matching and material selection, leading to increased product diversity and production complexity.
Innovation Solution
A universal thermal-expansion compensator with a compensation pin and element featuring multiple stop receptacles and a holder, allowing flexible adjustment of expansion length to accommodate various headlamp designs, thereby reducing the need for multiple specific compensators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a universal thermal-expansion compensator with multiple stop receptacles is used, then adaptability to various headlamp designs is improved, but device complexity increases due to the need for multiple stop receptacles and adjustable mechanisms
Solution Approach 1:
The thermal-expansion compensator is designed with multiple stop receptacles and an adjustable compensation pin that can be positioned at different stops, enabling a single device to accommodate various headlamp designs and thermal expansion requirements. This universal design eliminates the need for model-specific compensators while maintaining precise geometric matching capabilities.
2Manufacturing precision
If precise geometric matching and material selection are performed for each vehicle model, then manufacturing precision is improved, but ease of manufacture deteriorates due to complex design and high development costs
Solution Approach 1:
The compensator design separates the geometric matching requirements into discrete, adjustable parameters through multiple stop receptacles positioned at specific intervals. This segmentation allows standardised manufacturing of the compensator body while enabling precise geometric adaptation through simple repositioning of the compensation pin, rather than requiring custom-designed compensators for each vehicle model.
3Adaptability or versatility
If product diversity is increased to accommodate different vehicle models, then adaptability is improved, but device complexity and production complexity increase
Solution Approach 1:
Instead of producing different compensator models for different vehicle models, the invention uses a universal compensator design with multiple stop receptacles that can be configured for various applications. This approach maintains product diversity and adaptability while significantly reducing production complexity, as only one compensator type needs to be manufactured with standardized materials and geometry.
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
Enables precise thermal compensation with a compact and adaptable design, reducing the complexity of headlamp systems and production costs while maintaining precise light distribution and minimizing the risk of blinding oncoming drivers.
Implementation Method 1
the compensation body of the compensation element can expand or contract freely in said holder along said compensation axis
Data Source
AI summary
The invention relates to a thermal-expansion compensator for holding a light module in a housing of a headlamp for a motor vehicle, comprising a compensation pin extending along a pin axis with a stop element, wherein the compensation pin can be connected to the housing by means of a connecting means, a compensation element with a compensation body extending along a compensation axis and at least two stop receptacles that are each formed for holding the stop element of the compensation pin, and a holder that is arranged rigidly on the light module.