Vehicle Ambient Lighting Structure With Concealed Retaining Mechanism
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Solution Overview
Problem
Conventional ambient lighting designs for vehicles are difficult to assemble, require high tooling costs, and do not effectively protect the lighting structure during manufacturing, making them costly and inefficient.
Innovation Solution
A lighting structure comprising a first portion with a retaining structure for an elongated lighting element and a fastening structure to attach to a vehicle panel, and a second portion that conceals the retaining structure, allowing for easy installation and cost-effective manufacturing by using snap-fit or heat-staked fastening elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional ambient lighting designs use extruded light pipes or light strings, then lighting function is achieved, but assembly difficulty increases and tooling costs increase
Solution Approach 1:
The lighting structure is divided into separate modular components: a housing, a lighting element, and a finisher. These segments can be manufactured independently using standard processes and then assembled together, reducing overall assembly complexity while maintaining lighting functionality.
Solution Approach 2:
The patent employs cost-effective materials and manufacturing methods such as injection-molded plastic housings and finishers, replacing expensive extruded light pipes. This approach reduces tooling costs and simplifies manufacturing while achieving the same ambient lighting effect.
2Ease of manufacture
If light pipe is installed directly to instrument panel with finishing piece, then lighting function is achieved, but assembly difficulty increases and protection during manufacturing is lost
Solution Approach 1:
The housing and finisher are designed as pre-assembled units with integrated mounting features. The lighting element is pre-positioned within the housing with retaining structures that secure it before final installation to the instrument panel, protecting the assembly during manufacturing processes.
Solution Approach 2:
The lighting element is nested within the housing, which is then nested within the instrument panel opening, with the finisher providing an outer protective layer. This nested structure protects the lighting element during manufacturing while simplifying the overall assembly process.
3Ease of manufacture
If injected light pipe assembly is compressed between interior and exterior finishers, then lighting function is achieved, but high tooling costs are required
Solution Approach 1:
The patent uses cost-effective injection-molded plastic components instead of expensive pre-formed light pipe assemblies. The housing and finishers are manufactured using standard injection molding processes, significantly reducing tooling costs while maintaining assembly integrity through designed mechanical features.
Solution Approach 2:
The patent combines the housing, lighting element retention, and mounting functions into a single integrated housing structure. This merging eliminates the need for separate compression assemblies and reduces tooling requirements while maintaining the strength and integrity of the final assembly.
4Ease of manufacture
If flexible light string is contained inside protective box, then lighting function is achieved, but cost effectiveness is reduced
Solution Approach 1:
The patent merges the protective housing with the mounting structure and lighting element retention features. This integration eliminates the need for separate protective boxes while providing adequate protection for the lighting element, significantly improving cost effectiveness.
Solution Approach 2:
The housing is designed as a segmented structure with open ends that allow the lighting element to be exposed for light emission while providing protection where needed. This selective protection approach reduces material costs compared to fully enclosed protective boxes.
Data Source
AI summary
A lighting structure for a vehicle includes a first portion and a second portion. The first portion includes a retaining structure configured to retain an elongated lighting element, and a fastening structure configured to attach the lighting structure to an interior vehicle panel. The second portion is attached to the first portion at a location spaced from the retaining structure, with a distal end of the second portion being spaced from the retaining structure such that the second portion conceals the retaining structure in a longitudinal direction of a vehicle when the lighting structure is attached to the interior vehicle panel.