Folded Metal Sheet Radiator for Vehicle Headlight Thermal Management
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Solution Overview
Problem
Existing optical modules for motor vehicle headlamps face manufacturing complexity and inefficiency due to the need for injection or extrusion steps in forming radiators, which can lead to increased production costs and thermal management challenges.
Innovation Solution
A single metal sheet with folds is used to form a radiator, eliminating the need for injection or extrusion, and allowing direct fixation of light sources and power supplies, enhancing thermal contact and heat dissipation through a crenellated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection or extrusion steps are used to form the radiator, then the radiator structure can be formed, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent changes the manufacturing approach from injection/extrusion processes to a folding process of metal sheets. This parameter change in the manufacturing method simplifies the process by eliminating complex molding steps while maintaining the radiator's structural integrity and heat dissipation functionality.
Solution Approach 2:
The radiator is divided into multiple metal sheets that are folded and assembled together. Each sheet can be prepared separately and then combined, which simplifies the manufacturing process compared to forming the entire radiator structure in one complex injection or extrusion step.
2Ease of manufacture
If a single metal sheet with folds is used to form the radiator, then the manufacturing process is simplified, but the thermal contact between power supply system and metal sheet must be ensured
Solution Approach 1:
The power supply system is integrated directly with the metal sheet structure, merging the electrical and thermal management functions into a unified design. This ensures reliable thermal contact while maintaining manufacturing simplicity, as the power supply system becomes part of the folded metal sheet assembly rather than a separate component requiring additional mounting steps.
3Temperature
If light sources are fixed directly on the metal sheet, then thermal contact is improved, but the structural integrity of the metal sheet must be maintained
Solution Approach 1:
The metal sheet is designed with localized reinforcement or specific structural features at the areas where light sources are fixed. This allows direct thermal contact between the light sources and metal sheet while maintaining the overall structural integrity of the sheet through localized quality enhancements rather than compromising the entire structure.
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 approach simplifies the manufacturing process, improves heat dissipation efficiency, and maintains optimal operating temperatures for the light sources, reducing the risk of thermal damage and enhancing the reliability of the optical module.
Implementation Method 1
a radiator comprising a metal sheet provided with a plurality of folds, each fold forming a heat dissipation fin, one or more light source(s), fixed to the metal sheet, and a power supply system power of each light source, the power supply system being in thermal contact with the metal sheet
Implementation Method 2
a fan able to send air between said fins
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~4
AI summary
The invention relates to an optical module for a motor vehicle projector, characterized in that it comprises: - a radiator (1) comprising a metal sheet (2) having a plurality of folds, each fold forming a heat dissipation fin, - one or more light source(s) (3), fixed on the metal sheet, and - an electrical power supply system (5) for each light source (3), the electrical power supply system (5) being in thermal contact with the metal sheet (2).