Dual PCB Assembly for Vehicle Headlights
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Solution Overview
Problem
The automotive industry faces challenges in mounting and assembling lighting systems due to the need for specific printed circuit boards with different configurations for right and left-hand side headlights, which is costly and time-consuming, especially when electronic light sources are changed.
Innovation Solution
A dual printed circuit board assembly with a first and second substrate, connected via a common panel for electrical insulation, allowing the same board to be used with different types and models of light sources, including solid state light sources, and capable of being mounted on both right and left-hand side headlights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different printed circuit boards are used for different light source configurations and right/left hand side headlights, then the lighting system can be adapted to different requirements, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent implements a universal printed circuit board design that can serve multiple functions: it supports different light source types (HID, LED, laser) through configurable mounting structures, and can be installed in both right-hand and left-hand side headlights without requiring mirror-image variants. This multi-functional approach eliminates the need for maintaining multiple specialized PCB designs, thereby reducing assembly complexity while preserving adaptability.
Solution Approach 2:
The printed circuit board is divided into functional modules: a common base structure providing electrical connections, and interchangeable mounting structures that can be configured for different light source types. This segmentation allows the core PCB to remain standardized while only requiring minimal configuration changes (such as component placement or mounting structure attachment) to adapt to different light source requirements, thus reducing overall assembly complexity.
2Adaptability or versatility
If different printed circuit boards are used for different light source configurations and right/left hand side headlights, then the lighting system can be adapted to different requirements, but the production cost increases
Solution Approach 1:
The patent implements a universal printed circuit board design that can serve multiple functions: it supports different light source types (HID, LED, laser) through configurable mounting structures, and can be installed in both right-hand and left-hand side headlights without requiring mirror-image variants. This multi-functional approach eliminates the need for maintaining multiple specialized PCB designs, thereby reducing assembly complexity while preserving adaptability.
Solution Approach 2:
The patent utilizes parameter changes in the form of configurable component placements and adjustable mounting structures on the PCB. By designing the board with adjustable parameters (such as component positions, mounting hole patterns, and electrical connection configurations), a single PCB design can accommodate different light source types and orientations without requiring separate manufacturing processes, thus reducing production costs while maintaining adaptability.
3Ease of manufacture
If a single printed circuit board is used for both right and left hand side headlights, then production costs are reduced, but the ability to provide different light patterns is compromised
Solution Approach 1:
The patent incorporates dynamic configurability into the PCB design through adjustable mounting structures and reconfigurable electrical connections. This allows the same physical PCB to be dynamically adapted to different configurations (right-hand or left-hand side, different light source types) through simple adjustments or component placements, rather than requiring different fixed designs. This dynamic approach maintains the ability to provide different light patterns while using a single standardized PCB platform.
Solution Approach 2:
The patent utilizes parameter changes in the form of configurable component placements and adjustable mounting structures on the PCB. By designing the board with adjustable parameters (such as component positions, mounting hole patterns, and electrical connection configurations), a single PCB design can accommodate different light source types and orientations without requiring separate manufacturing processes, thus reducing production costs while maintaining adaptability.
Data Source
AI summary
A dual printed circuit board assembly for vehicle lights, the dual printed circuit board including a dual printed circuit board and a dual connector. The dual printed circuit board having a first substrate with a first layout, a second substrate opposite to the first substrate with a second layout, and a common panel that supports the first substrate on a first side and the second substrate on a second side, wherein the first layout is populable by a first plurality of light sources to be used in a first light of the vehicle lights and the second layout is populable by a second plurality of light sources to be used in a second light of the vehicle lights. The dual connector having a first jumper connector electrically connected to the first layout, and a second jumper connector opposite to the first jumper connector and electrically connected to the second layout.