Illuminating Device Electroplated Housing Electrodes
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Solution Overview
Problem
The assembly of illuminating devices, such as vehicle lamps, involves labor-intensive and costly processes due to the need for hot-melting heat rivets, leading to increased production costs and time.
Innovation Solution
The use of an insulative housing with layered active and conductive metal parts forming electrodes, which are integrated into through holes to electrically connect light sources, reducing the number of components and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat rivets are hot-melted to interconnect the substrate and lamp cover, then reliable electrical connection is achieved, but production cost and assembling time increase
Solution Approach 1:
The patent merges the electrode structure with the housing by forming conductive segments directly on the housing body through electroplating. The first conductive segment is formed on the inner wall of the through hole, the second conductive segment on the outer surface, and they are electrically connected via the housing material itself, eliminating the need for separate heat rivet components and hot-melting operations.
Solution Approach 2:
The patent replaces the mechanical hot-melting process with an electrochemical deposition process. Instead of using heat and mechanical pressure to melt and bond heat rivets, the invention uses electroplating to directly form conductive metal segments on the housing, which are then electrically connected through the conductive housing material.
2Adaptability or versatility
If multiple separate components (lamp cover, flexible PCB, heat rivets, substrate) are used, then functional requirements are met, but device complexity and labor cost increase
Solution Approach 1:
The patent combines multiple functional components into an integrated housing structure. The housing serves as both the protective enclosure and the electrical connection medium, with conductive segments formed directly on it. This integration reduces the total component count while maintaining all necessary functions including mechanical support, electrical conduction, and structural integrity.
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: it provides mechanical protection for internal components, serves as an electrical conductor for power transmission through its conductive segments, and acts as a mounting structure for the light-emitting element. This multi-functionality reduces the need for separate specialized components.
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 configuration results in reduced production costs and simplified manufacturing, while also providing stable electrical transmission and improved heat dissipation efficiency for the illuminating device.
Implementation Method 1
forming a pair of layered active metal parts respectively on the hole walls of the through holes and extending from the hole walls to a portion of each of the front and rear surfaces; forming first layered metal parts respectively on the layered active metal parts
Data Source
AI summary
An illuminating device includes an insulative housing, at least two electrodes and a light source. The insulative housing has opposite front and rear surfaces and is formed with at least two through holes. Each of the through holes is defined by a hole wall and penetrates the front and rear surfaces. Each of the electrodes includes a first conductive segment formed proximate the front surface, a second conductive segment formed proximate the rear surface, and a connecting segment formed inside a respective one of the through holes and interconnecting electrically the first and second conductive segments. The light source is disposed on the front surface and includes first and second connecting terminals each being electrically coupled to the first conductive segment of a corresponding one of the electrodes.