Vehicle Light Harness Integration for Connector-Free Assembly
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Solution Overview
Problem
Current vehicle light assembly methods require manual plug connections with mechanical connectors, leading to increased costs and complexity due to extra cable lengths needing protection and additional components, occupying valuable space.
Innovation Solution
Designing the cable harness as an integral part of an injection-molded component with exposed connection terminals and a holding mechanism for light units, using heat-resistant materials to withstand encapsulation and integrate light guides, and employing press-fit pins for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual plug connections with mechanical connectors are used, then electrical connection between circuit carriers is achieved, but assembly complexity and costs increase due to extra cable lengths needing protection and additional components
Solution Approach 1:
The patent merges the cable harness with the injection-molded holding component into a single integrated structure. The cable harness is embedded directly into the holding component during injection molding, eliminating the need for separate mechanical connectors and reducing assembly steps while maintaining reliable electrical connections between circuit carriers.
Solution Approach 2:
The injection-molded holding component serves multiple functions simultaneously: it holds the light units, provides structural support, and integrates the cable harness for electrical connections. This multi-functional design eliminates the need for separate cable management components and reduces overall device complexity.
2Ease of operation
If extra cable lengths are provided for manual plug connections, then assembly flexibility is improved, but costs and device complexity increase due to need for protection against mechanical influences
Solution Approach 1:
The cable harness is combined with the holding component in a single injection-molded part. The cables are embedded within the molded structure, which provides inherent protection against abrasion and crushing without requiring additional protective components like cable guides or cable ties.
Solution Approach 2:
The injection-molded holding component acts as a protective shell that encloses and protects the integrated cable harness. This molded structure provides mechanical protection against adverse influences while maintaining the necessary flexibility for assembly.
3Object-affected harmful factors
If additional components such as cable guides or cable ties are used, then cable protection is improved, but costs and space requirements increase
Solution Approach 1:
The protective function previously requiring separate cable guides and cable ties is integrated into the holding component itself. The injection-molded structure incorporates cable routing channels and protective features directly into its design, eliminating the need for additional protective components and reducing overall space requirements.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a vehicle light (1) comprising: - at least two light units (2a, 2b), wherein each light unit (2a, 2b) comprises at least one light source (2a1, 2b1) and at least one circuit carrier (2a2, 2b2), - and at least one cable harness (3) for electrically connecting at least one circuit carrier (2a2) of a first light unit (2a) to at least one circuit carrier (2b2) of a second light unit (2b), wherein the at least one cable harness (3) is designed as an integral part of an injection-molded component (4), wherein the at least one cable harness (3) has connection terminals (3a', 3b') at its ends (3a, 3b) which are exposed on the surface of the injection-molded component (4) for contacting the respective circuit carrier (2a2, 2b2), wherein the injection-molded component (4) is designed as a holding means which is configured to hold at least one of the at least two light units (2a, 2b) to hold,wherein the injection-molded component (4) has a fastening means (4a) for attachment to a vehicle component (5).