Vehicle Vanity Lamp Mounting With Flange and Rotating Wings
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Solution Overview
Problem
The existing methods for installing a vanity lamp on a vehicle headliner require additional manufacturing steps, increased costs, and the use of jigs for accurate positioning, which complicates the assembly process.
Innovation Solution
A vehicle vanity lamp design that includes a flange and wings, allowing the lamp to be inserted through a mounting hole in the headliner, with the wings unfolding to securely provisionally couple the lamp to the headliner without the need for a lamp plate or additional jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lamp plate is manufactured and attached to the headliner for mounting the vanity lamp, then the vanity lamp can be securely mounted, but the manufacturing cost increases and the assembly process becomes more complex
Solution Approach 1:
The flange is integrated directly into the vanity lamp body, merging the mounting structure with the lamp itself. This eliminates the need for a separate lamp plate, reducing assembly complexity while maintaining secure mounting through the flange's direct contact with the headliner edge
Solution Approach 2:
The flange serves multiple functions: it provides structural support for the lamp, enables secure mounting to the headliner, and eliminates the need for additional mounting components. This multi-functional design reduces both part count and assembly complexity
2Reliability
If a lamp plate is manufactured and attached to the headliner, then the vanity lamp can be mounted, but additional manufacturing steps and costs are required
Solution Approach 1:
The mounting function is merged into the lamp body through the integrated flange, eliminating the need for a separate lamp plate component. This reduces manufacturing costs by removing an entire sub-assembly while maintaining secure mounting capability
Solution Approach 2:
The unnecessary lamp plate component is extracted from the mounting system, leaving only the essential flange integrated into the lamp body. This simplification reduces manufacturing complexity and cost without compromising mounting reliability
3Manufacturing precision
If a jig is used for provisional coupling of the vanity lamp to the headliner, then accurate positioning is achieved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The flange's geometry is designed to self-align and self-position against the headliner edge during insertion. This self-positioning mechanism achieves accurate positioning without requiring external jigs or complex alignment tools, reducing assembly complexity while maintaining precision
4Device complexity
If the flange is inserted to pass through the headliner, then the vanity lamp can be mounted without a lamp plate, but the flange must be in close contact with the headliner edge for secure mounting
Solution Approach 1:
The mounting contact is transitioned from a face-contact arrangement (requiring high positioning precision) to an edge-contact arrangement where the flange contacts the headliner edge. This dimensional change in the contact interface reduces the sensitivity to positioning errors while maintaining secure mounting
Data Source
AI summary
A vanity lamp is inserted such that a flange is in close contact with an edge of a mounting hole formed in a surface of a headliner, and a wing is rotated to be in close contact with the surface of the headliner to perform provisional assembling such that an edge portion of the mounting hole is provisionally assembled between the flange and the wing, thereby provisionally assembling the vanity lamp to the headliner without additionally mounting a lamp plate. Particularly, the wing is formed on the vanity lamp to be forcibly rotated, and a ledge is formed on a foldable central portion such that the wing is hooked on the ledge while facing the flange, and thereby anyone can easily and conveniently perform assembly by easily provisionally assembling the vanity lamp in the mounting hole.