Vehicle Lamp Lens Positioning via Three-Projection Support
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Solution Overview
Problem
Conventional vehicle lamps have limitations in accurately forming light-distribution patterns, which affects their performance and efficiency.
Innovation Solution
A vehicle lamp design featuring a metal light-source stage with a support portion that includes three projections to position a lens member along the optical axis, ensuring precise alignment and simplifying dimension control during manufacturing, combined with positioning mechanisms for accurate placement of the light source and lens member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional vehicle lamps use simple support structures for the lens member, then the manufacturing process is simpler, but the accuracy of light-distribution patterns deteriorates
Solution Approach 1:
The support portion is segmented into three distinct projections instead of a single support structure. Each projection independently contacts a specific surface of the lens member's leg, dividing the support function into multiple discrete points that collectively achieve precise positioning and accurate light-distribution patterns.
Solution Approach 2:
The lens member's own geometry (its leg with specific surfaces) is utilized as part of the positioning mechanism. The three projections of the support portion engage with three specific surfaces of the leg, allowing the lens member's structure itself to contribute to the positioning accuracy without requiring additional complex external fixtures.
2Measurement precision
If the lens member is positioned with multiple support points, then the positioning accuracy improves, but the device complexity increases
Solution Approach 1:
Each of the three projections has a specific function of contacting a specific surface of the lens member's leg. This local specialization of support points ensures that each contact point contributes optimally to positioning accuracy in its specific direction, rather than using a uniform support structure.
Solution Approach 2:
The support portion uses three asymmetrically arranged projections rather than symmetric or uniform support points. This asymmetric arrangement is specifically designed to match the geometry of the lens member's leg, enabling precise positioning through non-uniform contact points that correspond to the asymmetric optical requirements.
3Manufacturing precision
If conventional lamps use complex positioning mechanisms, then the light-distribution accuracy improves, but the manufacturing cost increases
Solution Approach 1:
The positioning function is merged into the support portion structure itself. The three projections that provide support also simultaneously provide positioning, eliminating the need for separate positioning mechanisms. This integration achieves precise light-distribution patterns while maintaining manufacturing simplicity and cost-effectiveness.
Solution Approach 2:
The support portion serves multiple functions: it provides mechanical support for the lens member, positions the lens member accurately in three dimensions, and ensures proper optical alignment. This multi-functionality is achieved through the simple three-projection structure, avoiding the need for additional dedicated positioning components.
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 patterns formed by the vehicle lamp, improves heat dissipation efficiency, and simplifies the manufacturing process while maintaining cost-effectiveness.
Implementation Method 1
light from a light source disposed in a lamp chamber is refracted by a lens portion and is then emitted
Data Source
AI summary
A vehicle lamp according to an aspect of the present invention includes a light source, a metal light-source stage including a light-source mounting portion, and a lens member that emits light from the light source toward the front of the lamp. The light-source stage includes a support portion for the lens member. The lens member includes a leg projecting toward the light-source stage and having an end that is supported by the support portion. The support portion includes three projections that abut the leg in a state in which the leg is supported by the support portion and position the lens member in a direction of an optical axis. The three projections are positioned relative to one another such that at least a portion of the light source lies in an extension range of a triangle with vertices given by the three projections.