Vehicle Lamp Holder Layout for Precise Lens and Light Source Alignment
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Solution Overview
Problem
Existing vehicle lamp designs suffer from inaccuracies in positioning the projection lens and light source unit due to the spacing and interposition of multiple members, which affects the accuracy of light distribution.
Innovation Solution
A vehicle lamp design where the substrate with the light source and the lens are positioned directly to a common holder, with the lens secured from the backside, allowing for improved alignment and reduced thickness through laser welding, eliminating the need for rotating components during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple members are interposed between the projection lens and light source unit, then the structural stability is improved, but the positioning accuracy deteriorates
Solution Approach 1:
The patent merges multiple separate members (lens holder, base member, heat sink) into a single integrated holder that directly positions both the projection lens and light source unit. This integration eliminates the need for multiple interposed members while maintaining structural stability, thereby improving positioning accuracy between the lens and light source.
2Temperature
If the projection lens and light source unit are spaced apart, then the heat dissipation is improved, but the positioning accuracy deteriorates
Solution Approach 1:
The integrated holder combines the lens positioning function and light source mounting function into a single structure. The holder includes a lens positioning portion and a light source unit mounting portion that are structurally connected, ensuring accurate relative positioning while providing integrated heat dissipation pathways from the light source to the holder structure.
3Adaptability or versatility
If components are positioned from opposite sides, then the assembly flexibility is improved, but the manufacturing complexity increases
Solution Approach 1:
Instead of positioning the lens and light source from opposite sides of the holder, the patent inverts the approach by positioning both components from the same side (front side) of the holder. The lens is positioned in a lens positioning portion and the light source unit is mounted in a light source unit mounting portion, both accessible from the front, thereby simplifying the manufacturing process while maintaining assembly flexibility.
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 configuration enhances the accuracy of light distribution and reduces the vehicle lamp's thickness by improving the positioning of the substrate and lens, while also simplifying the manufacturing process and reducing glare.
Implementation Method 1
The lens and the substrate are positioned to the holder in a laser welding manner from the same side
Data Source
AI summary
A vehicle lamp includes a metal plate having a light source mounted thereon, a lens that light emitted from the light source enters and passes through to exit forward, and a holder that holds the lens. The metal plate and the lens are positioned to the holder.