Flat Flexible Circuit for Movable Headlight Module
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Solution Overview
Problem
The existing electrical connections in motor vehicle headlamps, particularly for movable optical modules, face challenges with rigidity and limited conductivity, which restricts the freedom of movement and durability due to the use of traditional round cables.
Innovation Solution
A flexible sheet-like electrical connection system with mechanical securing means and conductive tracks, allowing for multiple conductors to be used without increasing rigidity, and providing mechanical protection and guidance for mobility, enabling reliable and durable transmission of electrical flows even with frequent movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional round cables are used for electrical connection, then the connection is mechanically robust, but the rigidity increases and freedom of movement is restricted
Solution Approach 1:
The patent replaces traditional round cable bundles with a flat flexible printed circuit board (FPCB) that has the same surface area. The FPCB's thin film structure allows it to bend and deform easily, providing freedom of movement for the optical module while maintaining mechanical robustness through its distributed conductor track design. The flat flexible structure can accommodate movements without the rigidity constraints of traditional round cables.
2Quantity of substance
If more conductors are added to carry multiple electrical flows, then the conductivity capacity increases, but the device complexity and rigidity increase
Solution Approach 1:
The patent merges multiple individual conductors into a single flat flexible printed circuit board that contains multiple conductor tracks distributed across its surface. This consolidation reduces the overall structural complexity compared to managing multiple separate round cables, while still providing the capacity to carry multiple electrical flows simultaneously through the integrated conductor network.
Solution Approach 2:
The patent transitions from traditional three-dimensional round cable bundles to a two-dimensional flat flexible printed circuit board layout. This dimensional change allows multiple conductor tracks to be distributed across the surface area, enabling high conductivity capacity for multiple electrical flows without increasing structural complexity or rigidity, as the flat structure maintains flexibility.
3Object-affected harmful factors
If traditional round cables are used, then the mechanical protection is sufficient, but the durability under frequent movement is reduced
Solution Approach 1:
The patent uses a flat flexible printed circuit board with a protective protective layer that provides mechanical protection equivalent to traditional round cables. The flexible nature of the thin film structure allows it to withstand frequent movements, bending, and deformation without damage, significantly improving durability compared to rigid round cable assemblies that are susceptible to fatigue and breakage under repeated movement.
4Adaptability or versatility
If the optical module is mounted movably for dynamic lighting functions, then the adaptability increases, but the electrical connection reliability deteriorates
Solution Approach 1:
The patent employs a flat flexible printed circuit board that inherently accommodates the movable mounting of the optical module. The flexible thin film structure allows the electrical connection to maintain reliability during dynamic positioning movements, as it can bend and deform with the module's motion without compromising electrical contact or structural integrity.
Solution Approach 2:
The patent designs the electrical connection system to be dynamic rather than static. The flat flexible printed circuit board is specifically engineered to accommodate the range of motion required for dynamic lighting functions, maintaining reliable electrical connection throughout the movement envelope. This dynamic design ensures that the electrical connection adapts to the module's positioning changes without failure.
Data Source
Figure 1~2
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Figure 12~14
AI summary
The module (1) has a light generator with a light source e.g. discharge lamp (3), connected to an optical system (2). A mounting structure (4) i.e. framework, is movably mounted on a support (5). An electric connection unit has a flexible element (7) whose electric conductors (9) electrically connect the module to remote power supply and/or optical module operation controlling units. The element is connected between the structure and the support such that mechanical connection points have a limited liberty of movement in space when compared to a round rope connection. The flexible element is a flat cable or a flexible printed circuit that is formed by roll deposition of a conductive material. The element has width larger than thickness of the element.