Foldable PCB Light Support for Compact Automotive Heat Management
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Solution Overview
Problem
Conventional PCBs face challenges in accommodating high power semiconductor devices for HD vehicle lighting due to space constraints and heat dissipation issues, necessitating larger sizes and additional connectors, which are costly and inflexible.
Innovation Solution
A bendable and foldable PCB assembly comprising two rigid parts connected by a flexible part with a single or dual bendable portions, allowing components to be arranged at various angles, with heat-generating components separated to facilitate effective cooling and space-saving design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the size of the PCB is increased to accommodate more components for HD lighting, then the number of components that can be mounted is improved, but the available space in vehicle lamps is limited and heat dissipation becomes more difficult
Solution Approach 1:
The PCB is divided into multiple separate PCB parts (first PCB part, second PCB part, third PCB part) that are interconnected through flexible connecting parts. This segmentation allows the components to be distributed across multiple smaller boards rather than requiring a single large PCB, thereby reducing the area occupied in the vehicle lamp while accommodating the same number of components.
Solution Approach 2:
The flexible connecting parts enable the PCB parts to be arranged in three-dimensional space rather than being constrained to a single flat plane. This allows the PCB assembly to fold and bend, utilizing vertical space and angular arrangements to pack more components into a smaller overall footprint within the vehicle lamp housing.
2Illumination intensity
If high power semiconductor devices are mounted on the PCB for HD lighting, then the lighting performance is improved, but heat generation increases and becomes difficult to dissipate
Solution Approach 1:
Heat-generating components are segregated onto specific PCB parts (first PCB part) that are separated from other components through flexible connecting parts. This spatial segmentation of thermal zones allows for targeted heat management strategies, such as directing cooling resources to specific high-heat areas rather than requiring uniform cooling across the entire PCB assembly.
Solution Approach 2:
The flexible connecting parts can be designed with integrated heat dissipation features such as heat sinks or thermal management structures that extract heat from the PCB assembly. This allows the heat-generating components to be physically connected to external cooling mechanisms, effectively removing heat from the system.
3Adaptability or versatility
If conventional PCBs are used with harness and connectors to connect multiple PCBs, then the components can be distributed, but the assembly becomes more complex and expensive
Solution Approach 1:
The flexible connecting parts integrate multiple functions into a single component: they provide electrical connections between PCB parts, enable mechanical flexibility and bending, and can incorporate heat dissipation features. This eliminates the need for separate harnesses and connectors, simplifying the overall assembly while maintaining the ability to distribute components across multiple PCB parts.
Solution Approach 2:
The flexible connecting parts serve multiple purposes simultaneously: they act as electrical conductors, mechanical flexors, structural support elements, and potential heat dissipation pathways. This multi-functionality reduces the total number of components required in the assembly, lowering complexity and cost while achieving the same component distribution capability.
Data Source
AI summary
A light source support assembly for an automotive vehicle, the light source support assembly includes at least two rigid Printed Circuit Board (PCB) parts having a first rigid PCB part and a second rigid PCB part. The first rigid PCB part is mounted with a plurality of first components that are heat generating components and the second rigid PCB part is mounted with a plurality of second components that are components not generating heat or components generating less heat compared to the plurality of first components. A flexible connecting part interconnecting the first rigid PCB part and the second rigid PCB part, and includes at least one bendable portion configured to bend the light source support assembly.