Vehicle Lighting Unit Form-Fitting Optical Adapter
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Solution Overview
Problem
Existing vehicle lighting units face challenges in achieving precise and cost-effective component alignment and attachment, often requiring additional process steps and lacking in reliability and strength in their fastening mechanisms.
Innovation Solution
The solution involves a form-fitting, non-positive connection between the attachment optics and the holding body, where the fastening domes engage with a peripheral edge of the recess, eliminating the need for a subsequent fastening step, and incorporating a spring element for constant contact pressure and heat dissipation, along with an S-shaped cross-section for enhanced positioning and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fastening domes are inserted into recesses for precise alignment, then positioning accuracy is improved, but additional fastening process steps are required
Solution Approach 1:
The locking lugs are pre-formed on the peripheral edge of the recess at an acute angle to the printed circuit board plane, ready to engage with the fastening domes during insertion. This preliminary preparation eliminates the need for subsequent fastening steps, as the clamping action occurs automatically during the insertion process itself.
2Ease of manufacture
If simple press-fit connection is used, then manufacturing effort is reduced, but connection strength and reliability are insufficient
Solution Approach 1:
The locking lugs are designed with a curved geometry that engages the fastening domes through a clawing action. The acute angle of the locking lugs relative to the printed circuit board creates a mechanical interlock that significantly enhances connection strength while maintaining the simplicity of the press-fit insertion process.
3Reliability
If multiple fastening steps are implemented, then attachment reliability is improved, but process complexity increases
Solution Approach 1:
The positioning and fastening functions are merged into a single integrated structure. The locking lugs are formed as part of the recess structure, combining the positioning feature with the fastening mechanism. This allows the fastening dome to simultaneously achieve precise positioning and secure attachment in one insertion action, eliminating the need for separate fastening steps.
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 approach reduces manufacturing effort, increases process reliability, and provides a strong, reliable attachment while ensuring precise positioning and efficient heat dissipation, enhancing the lighting unit's performance and durability.
Implementation Method 1
The holding body has a spring element on a side facing away from the printed circuit board, which spring element is supported against a support frame in the assembly position. Advantageously, the spring element enables a constant contact pressure, by means of which the printed circuit board and the attachment optics are pressed against the cover frame.
Implementation Method 2
the holding body enables the heat generated in the lighting unit to be dissipated quickly, so that it also acts as a heat sink
Data Source
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AI summary
The invention relates to a lighting unit for vehicles having a light source arranged on a circuit board and having an optical adapter arranged in front of the light source in the light emission direction which has at least one mounting dome on a side facing the circuit board, by means of which the optical adapter is connected in a form-fitting manner in the installation position to a holding body, with the mounting dome engaging in a recess of the holding body adjacent to a rear side of the circuit board facing away from the light source, wherein a peripheral edge of the recess is at least partially engaged with a mantel surface of the mounting dome in the installation position.