Vehicle Light Guide With Integrally Formed Lens And Deformable Attachment

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Solution Overview

Problem

Existing vehicle light systems fail to provide effective ambient and feature lighting that is both aesthetically pleasing and cost-efficient, often resulting in non-uniform light output and high production costs.

Innovation Solution

A light system integrated into a vehicle's trim panel using a flexible light guide with an integrally formed lens and deformable attachment mechanism, which is compressively retained within an aperture, providing uniform light dispersion and reducing fabrication costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If traditional rigid light guides are used, then structural stability is improved, but design flexibility and ability to reach inaccessible locations deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoiddesign flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent employs a flexible light guide constructed from elastomeric or thermoplastic materials that can be deformed during installation to reach complex or inaccessible locations within the vehicle interior, while maintaining sufficient structural integrity to guide light effectively once installed

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of repair

If multiple separate components (light guide, lens, attachment mechanism) are used, then ease of repair is improved, but device complexity and production costs worsen

Engineering Contradiction:

Improvecomponent replaceabilityVSAvoidnumber of parts

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The patent integrates the light guide, lens, and attachment mechanism into a single monolithic component formed through injection molding, eliminating the need for separate parts while maintaining the functional benefits of each individual component

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If complex multi-part assembly is used, then manufacturing precision is improved, but ease of manufacture and production costs worsen

Engineering Contradiction:

Improvealignment accuracyVSAvoidfabrication cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines multiple components into a single injection-molded part, which ensures precise alignment of optical elements during manufacturing while significantly reducing production complexity and costs compared to assembling multiple separate components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes injection molding parameters and material selection (elastomeric or thermoplastic) to achieve the desired optical and mechanical properties in a single manufacturing process, eliminating the need for subsequent assembly operations

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional light guides are used, then production cost is reduced, but light dispersion uniformity and perceived quality worsen

Engineering Contradiction:

Improveproduction costVSAvoidlight dispersion uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The flexible nature of the elastomeric or thermoplastic light guide allows for better conformability to mounting surfaces and more uniform light distribution across the illumination area, improving perceived quality while maintaining cost-effectiveness through single-step injection molding

Inventive Principle:

Principle #30Flexible shells and thin films

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

The solution offers improved light dispersion, increased design flexibility, and higher perceived quality while maintaining a soft touch and reducing production costs, allowing for installation in previously inaccessible locations within the vehicle.

Implementation Method 1

A light guide is disposed within the aperture. The light guide has a proximal portion operably coupled with a light source

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

A lens is integrally formed with the light guide and is disposed at a distal portion of the light guide

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 3

A deformable attachment mechanism is integrally formed on the light guide between the proximal and the distal portions of the light guide. The light guide is compressively retained within the aperture by a forward portion of the attachment mechanism

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10759339B2Vehicle light system

Publication Date: 2020.09.01 FORD GLOBAL TECH LLC

AI summary

A light system for a vehicle is provided herein. The light system includes a trim member defining an aperture. A light guide is disposed within the aperture. The light guide has a proximal portion operably coupled with a light source. A lens is integrally formed with the light guide and is disposed at a distal portion of the light guide. A deformable attachment mechanism is integrally formed on the light guide between the proximal and the distal portions of the light guide. The light guide is compressively retained within the aperture by a forward portion of the attachment mechanism and a rearward portion of the lens.