Vehicle Lamp Joint Structure for Cost Reduction
Solution Overview
Problem
The high manufacturing costs and complexity of producing long vehicle lamps, particularly due to the need for large molds and time-consuming fastening processes, which also limit miniaturization and increase space requirements.
Innovation Solution
A vehicle lamp design featuring a joint structure that connects multiple divided parts along the longitudinal direction, using claws and corresponding holes for easy assembly and a light leakage suppression structure to prevent optical defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single large mold and molding machine are used to manufacture a long vehicle lamp, then the manufacturing precision and structural integrity are improved, but the manufacturing cost and device complexity increase significantly
Solution Approach 1:
The vehicle lamp is divided into multiple short parts along the longitudinal direction, each manufactured separately using small molds and molding machines. These segmented parts are then connected through a joint structure to form the complete long lamp, eliminating the need for large-scale manufacturing equipment and reducing costs.
2Strength
If a fastening structure such as screwing or caulking is used to connect multiple short parts, then the connection strength is improved, but the manufacturing time and operation complexity increase
Solution Approach 1:
The joint structure merges multiple functions into a single integrated component: it provides mechanical connection strength, enables simple assembly through snap-fit engagement, and eliminates the need for separate fastening operations. The claws on one part engage with recesses on adjacent parts, creating a strong connection without requiring screws, rivets, or caulking operations.
3Reliability
If a fastening structure is installed on the part, then the connection reliability is improved, but the space requirements and part miniaturization are limited
Solution Approach 1:
The fastening functionality is nested within the lamp parts themselves through integrated claw and recess structures. The claws are formed as protrusions from the main body of one part, while corresponding recesses are formed in adjacent parts, allowing the connection mechanism to be embedded within the part geometry rather than requiring external fastening components.
4Device complexity
If multiple short parts are connected to form a long lamp, then the manufacturing cost is reduced, but the workability of connecting the parts may be impaired without an appropriate joint structure
Solution Approach 1:
The joint structure enables self-aligning and self-locking connection between parts. The claw and recess geometry is designed so that when parts are brought together, the claws automatically engage with the recesses without requiring precise manual alignment or additional fastening operations. This self-service mechanism greatly improves the ease of manufacture while maintaining connection reliability.
Data Source
AI summary
A vehicle lamp includes a long lamp component, and the lamp component includes a plurality of divided parts arranged in a longitudinal direction thereof and interconnected by a joint structure. The joint structure includes a first claw configured to connect upper surfaces of two adjacent divided parts of the plurality of divided parts and a first claw receiving hole fitted into the first claw, and a second claw configured to connect lower surfaces of the two divided parts and a second claw receiving hole fitted into the second claw.