Circuit Carrier Positioning for Precise Automotive Light Alignment
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Solution Overview
Problem
Existing methods for positioning and aligning semiconductor light sources in automotive lighting systems, such as headlights or taillights, lack the necessary precision and accuracy, requiring optical inspections that complicate the manufacturing process.
Innovation Solution
A device that uses bores and stop elements to precisely position semiconductor light sources relative to an optical system, allowing for precise alignment without optical inspection, by determining the target positions of the light-emitting area relative to the optical system through bores and fixing the circuit carrier in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical inspection is used to position semiconductor light sources, then positioning accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces optical inspection systems with a purely mechanical positioning system using bores, stop elements, and reference points. The mechanical features physically constrain the circuit carrier to achieve precise positioning without requiring complex optical measurement and adjustment equipment.
Solution Approach 2:
The positioning features (bores, stop elements, reference points) are pre-installed on the circuit carrier and optical system components during manufacturing. This preliminary preparation enables accurate positioning to be achieved automatically during assembly without requiring subsequent optical inspection or adjustment.
2Manufacturing precision
If optical inspection is used for alignment, then positioning precision is improved, but productivity decreases
Solution Approach 1:
The patent eliminates time-consuming optical inspection processes by using mechanical positioning features that automatically ensure accurate alignment during assembly. The bores and stop elements provide immediate mechanical guidance, allowing workers to quickly and accurately position components without prolonged measurement and adjustment cycles.
Solution Approach 2:
The positioning system is designed to be self-aligning through the interaction of complementary mechanical features (bores fitting over stop elements, reference points matching reference areas). This self-service mechanism automatically achieves precise alignment without requiring external inspection equipment or skilled adjustment operations.
3Manufacturing precision
If reference points are arranged on circuit carrier, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into the reference points and bores: they serve as positioning references, alignment guides, and mechanical constraints simultaneously. These simple geometric features perform multiple positioning tasks for different components (circuit carrier, optical system, semiconductor light sources) without requiring separate complex positioning mechanisms for each.
Solution Approach 2:
The patent combines the reference points, bores, and stop elements into a unified mechanical positioning system that works together as an integrated whole. Rather than using separate positioning mechanisms for different components, all positioning functions are merged into a coordinated system of complementary mechanical features that achieve precise alignment across multiple components.
Data Source
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AI summary
The invention relates to a method for arranging a circuit carrier (30) comprising at least one semiconductor light source (32) in a specified position relative to an optical system (20) of a lighting device of a motor vehicle.