Minnesota Rubber and Plastics News: New Dual Function SUV Backup Utility Light

New Dual Function SUV Backup Utility Light Has Unique Molded Components Designed And Supplied By Minnesota Rubber & Plastics

Minneapolis, Minnesota: Designing and sourcing a new backup light for sport utility vehicles was a challenge presented to Minnesota Rubber & Plastics. Traditionally a supplier of custom rubber and plastic molded components, the company is increasingly a designer and supplier of complete products such as the new Light Buster(TM) backup utility light for its originator Moto Trix, Inc.

	New, dual function SUV backup utility light called the Light Buster has unique molded part features from Minnesota Rubber and Plastics. The device plugs directly under rear bumper into a 7 pin round receptacle, which is standard on most SUV's.

Light Buster working prototype (left) and final molded assembly (right). Developmental work, including mold design through to volume production, took just eleven months and was handled completely by Minnesota Rubber and Plastics.

Light Buster is a dual function back-up or utility light which plugs directly into any 7-way standard 7 pin round RV/trailer receptacle. Producing 50-watts of very bright white light, it provides extra light behind your vehicle when you really need it - loading the vehicle, plowing snow, setting up camp and hooking up a trailer.

Originated by Moto Trix partners, Chris Kregness and Harry Webster, the two developed an operating prototype but needed design and manufacturing assistance to launch the product into the automotive aftermarket.

We heard about Minnesota Rubber & Plastics experience designing and manufacturing a complete line of bakeware for the cooking market, reported Chris Kregness. We also knew they had large scale manufacturing capabilities having supplied molded seals and other devices to the automotive industry for many years. So we went to them for recommendations both for design and manufacturing assistance. With their help, we went to market in less than a year and are now distributing large quantities of the Light Buster to automotive supply houses.

The original Light Buster prototype, developed by Kregness and Webster, was made with off-the-shelf components that included base, lens, bulb and switch. Minnesota Rubber & Plastics refined this original concept into a patent-pending dual function design, providing 3D prints and 2D models, working prototypes and market test samples prior to sourcing production to its Chinese manufacturing partner.

Rugged Design Withstands All-Weather Driving Conditions

Ruggedness to withstand a SUV’s backsplash in all-weather driving conditions and then function perfectly was critical in our designing the assembly, reported Ted Ahrenholtz, Technical Sales Support Manager for Minnesota Rubber & Plastics. We designed a wear-resistant base, injection molded of nylon, which can be rotated manually into either of two operating modes - backup light when the vehicle is shifted into reverse and utility light mode used when parked. The dual function design really adds value to the product and is regulated by a special micro switch mounted inside the Light Buster base. When the base elements are turned, a small key inside actuates the micro switch, switching into the selected operating mode. The two rotating base components have a special O-ring seal (EPDM - ethylene propylene diene monomer) which facilitates smooth rotation and also acts as a barrier to seal out moisture and dirt.

Light Buster components included design features that eliminated the need for fasteners and welding. The O-ring and gasket facilitates easy operation while protecting the assembly from moisture and dirt.

We designed the lens of polycarbonate material which effectively magnifies and disperses the 50 watt halogen light (1,000,000 measured candle power) over a wide area behind the vehicle, said Ahrenholtz. The lens is threaded around its circumference and screws tightly into the threaded base. This allows for easy bulb replacement when necessary. For further moisture and contaminant protection, a flat EPDM rubber gasket seals the screwed together lens and base. Inside, a hard chrome plated reflector, stamped from cold rolled steel, holds a standard halogen bulb socket. This socket connects to two glass insulated, high-temperature resistant wires which lead to the vehicle’s connecting receptacle, said Ahrenholtz.

Design Eliminates Need For Interior Fasteners

Some clever design work of the Light Buster base provides small “fingers” strategically positioned in the interior that locate, snap and lock components together tightly without the need for special fasteners or welding operations. Also, the micro switch is heat staked permanently into position so no fasteners are required. The base has an external keyway feature, which helps users align it quickly for easy installation even in low light conditions. A locking cleat provides positive retention. Measuring just 6 inches long with 1-5/8 inch base receptacle and 3 inch diameter lens, the Light Buster has no external connecting cords or wires, weighs only 8 ounces, and stores anywhere in a vehicle including a small glove box.

Ahrenholtz stated, By partnering with Moto Trix in a co-managed design and manufacturing supply effort, we were able to maintain highest quality, and meet quantity requirements and price targets for the demanding and very competitive automotive aftermarket.

Dual Function SUV Backup Utility Light

Chris Kregness (left) and Harry Webster (right) are partners in Moto Trix, Inc., which markets automotive aftermarket products such as the Light Buster.

*Light Buster is a trademark of Moto Trix, Inc.