Vehicle Light Module With Integral Plug
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Solution Overview
Problem
Existing external vehicle components with integrated light modules, such as door handles, are costly to manufacture and difficult to install due to the need for multiple parts and flexible electrical connections, which complicate the assembly and attachment process.
Innovation Solution
A single-piece light module with an integral plug, manufactured using injection molding, where the plug serves both as an electrical connector and a fastening mechanism, simplifying the manufacturing and installation by eliminating the need for separate electrical wires and additional installation steps, and incorporating features like latch connectors and reverse connection protection for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the light module is connected to the jack by means of flexible electrical wires, then the light module can be electrically connected to the vehicle system, but the manufacture becomes expensive and installation becomes difficult due to multiple individual parts
Solution Approach 1:
The plug is merged with the light module housing into a single integral component. The plug and housing are formed as one piece through injection molding, eliminating the need for separate electrical wires and connectors. This reduces the number of individual parts from multiple components to a single integrated unit, simplifying both manufacture and installation while maintaining reliable electrical connection.
2Reliability
If the plug is threaded through an opening in the sheet metal separately before installing the door handle, then the electrical connection can be established, but the installation process becomes difficult and time-consuming
Solution Approach 1:
The plug and light module are combined into a single integral component that is installed as one unit. The entire light module with integrated plug is pushed through the opening in the sheet metal together, eliminating the need for separate threading of the plug through the opening. This single-step installation process significantly reduces installation time and complexity while ensuring reliable electrical connection.
3Reliability
If multiple individual parts are used to create the door handle with light module, then the electrical connection can be established, but the manufacture becomes expensive
Solution Approach 1:
The plug and light module housing are merged into a single integral component manufactured through injection molding. This eliminates the need for separate manufacturing of individual parts such as the plug, housing, and electrical connectors. The single-shot injection molding process produces the complete light module assembly in one manufacturing step, significantly reducing manufacturing cost while ensuring reliable electrical connection through the integrated plug design.
4Reliability
If the plug is used only for electrical connection, then the electrical function is fulfilled, but additional fastening mechanisms and installation steps are required
Solution Approach 1:
The plug is designed to serve multiple functions simultaneously: it provides electrical connection between the light module and the vehicle system, and it also serves as the fastening mechanism to secure the light module to the vehicle. The integral plug structure incorporates both electrical contact elements and mounting features, eliminating the need for separate fastening mechanisms and reducing the total number of components required.
Data Source
AI summary
An exterior assembly component for a vehicle and a manufacturing method thereof, where the component is in the form of an exterior mirror, door handle, door sill, skirt or similar, the component including a light module having at least one lamp emitting visible light toward the outside, and a plug to supply the lamp with electrical energy, where the light module represents a separate component of the assembly component which can be mounted on the assembly component and wherein the plug is designed as a single part with the a case of the light module.