Door Mirror LED Unit Layout for Thermal Isolation and Stability
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Solution Overview
Problem
Existing light-emitting units for door mirrors face issues with LED instability and breakage due to heat transfer from the control unit, particularly when using flexible printed substrates, which also complicate connector connections.
Innovation Solution
A light-emitting unit design featuring a rigid first substrate part with a control unit, a separate rigid second substrate part made of aluminum and insulation, connected by a flexible printed substrate with a lower heat transfer rate, ensuring heat dissipation exceeds heat transfer, and a partition wall to block heat transfer to the LED.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid substrate is used to mount both the control unit and LED, then structural stability is improved, but heat transfer from the control unit to the LED increases causing LED breakage
Solution Approach 1:
The substrate is divided into two separate rigid substrates: a first rigid substrate for mounting the control unit and a second rigid substrate for mounting the LED. This segmentation prevents direct heat transfer from the control unit to the LED while maintaining structural stability of each component.
Solution Approach 2:
A flexible printed substrate serves as an intermediary connection between the first rigid substrate (control unit) and the second rigid substrate (LED). This intermediary allows electrical connection while providing thermal isolation, as the flexible printed substrate has lower thermal conductivity compared to rigid substrates.
2Object-affected harmful factors
If a flexible printed substrate is used to connect control unit and LED, then heat transfer is reduced, but LED position stability deteriorates and connector connection becomes difficult
Solution Approach 1:
The system is segmented into rigid substrates for stable component mounting (control unit and LED respectively) and a flexible printed substrate for connection. The rigid substrates provide stable mounting surfaces that ensure precise LED positioning and reliable connector connections.
Solution Approach 2:
The solution combines the advantages of rigid substrates (structural stability, precise positioning) and flexible printed substrates (thermal isolation, flexibility) into a unified structure. The rigid substrates handle mechanical stability requirements while the flexible printed substrate handles electrical connection with thermal isolation.
3Device complexity
If the control unit and LED are mounted on the same substrate, then device complexity is reduced, but heat dissipation becomes insufficient leading to LED breakage
Solution Approach 1:
The mounting substrate is segmented into two separate rigid substrates dedicated to different functions: one for the control unit and another for the LED. This physical separation creates distinct thermal zones that improve heat dissipation from the LED while maintaining relatively simple overall device structure.
Solution Approach 2:
The flexible printed substrate acts as a thermal intermediary with low thermal conductivity, blocking heat transfer from the control unit to the LED. This allows the control unit to generate heat without adversely affecting the LED's thermal environment.
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 design stabilizes the LED position, enhances connector connectivity, and reduces the likelihood of LED breakage by effectively dissipating heat, while minimizing space requirements.
Implementation Method 1
the amount of heat, which is generated in the control unit and reaches the second substrate part side through the connection part
Implementation Method 2
the amount of heat dissipated in the second substrate part
Data Source
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AI summary
To provide a light-emitting unit for a door mirror capable of improving a stability of LED's position and connectivity, while reducing a breakage possibility of the LED due to heat. The light-emitting unit for a door mirror is characterized in that it includes a rigid first substrate part having a connector part to receive a signal, and mounts a control unit thereon to cause an LED to emit light based on the signal; a rigid second substrate part provided separately from the first substrate part and mounts the LED thereon; and a connection part connecting the first substrate part to the second substrate part and having a circuit to cause a current signal transmitted from a first substrate part side to reach the LED's side, and the connection part has lower heat transfer rate than heat dissipation rate of the second substrate part.