Frangible PCB Layout for Automotive Lighting Variant Assembly
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Solution Overview
Problem
Automotive lighting devices require multiple configurations to meet different vehicle models, versions, and regulatory standards, leading to confusion and inefficiency in assembly due to similar circuit boards across variations.
Innovation Solution
An electronic substrate with frangible portions and conductive tracks of varying mechanical resistance allows for easy differentiation and customization by removing non-chosen circuits, enabling a single reference substrate to accommodate multiple options, and a housing design that prevents incorrect installation unless frangible portions are removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single reference electronic substrate is used for different lighting device variations, then manufacturing cost and complexity are reduced, but assembly confusion increases due to similar circuit boards
Solution Approach 1:
The electronic substrate is divided into multiple frangible portions, each corresponding to a specific circuit configuration. These portions can be easily separated to create different device variations from a single reference substrate, reducing manufacturing complexity while enabling clear assembly differentiation through physical separation.
Solution Approach 2:
Different regions of the substrate are designed with distinct frangible portions that have specific mechanical properties. Each frangible portion is localized to specific circuit areas, allowing operators to identify and separate only the necessary portions for the desired configuration, improving ease of operation during assembly.
2Adaptability or versatility
If multiple circuit configurations are integrated into a single substrate, then adaptability to different vehicle models and regulations is improved, but assembly time and cost increase due to differentiation difficulties
Solution Approach 1:
The substrate is pre-designed with frangible portions that anticipate different configuration needs. During assembly, operators simply need to separate the appropriate frangible portions rather than assembling entirely different substrates, significantly reducing assembly time while maintaining adaptability to various vehicle models and regulations.
Solution Approach 2:
The substrate transitions from a static, fixed-configuration design to a dynamic, reconfigurable design. The frangible portions allow the substrate to be dynamically adapted to different configurations by separating only the necessary sections, reducing assembly time and improving versatility.
3Ease of manufacture
If frangible portions are added to enable circuit separation, then ease of customization is improved, but substrate structural integrity is reduced
Solution Approach 1:
The mechanical properties of specific substrate regions are changed to create frangible portions. These portions have reduced mechanical strength compared to the rest of the substrate, allowing easy separation when needed while maintaining overall substrate integrity for handling and installation. The parameter change is localized only to the frangible portions.
Data Source
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Figure 2
AI summary
The invention is related to an electronic substrate (1) for an automotive lighting device. This electronic substrate (1) comprises a power input (2), a control unit (3) and first and second circuits, connecting, by their corresponding set of conductive tracks (4, 5), the power input (2) with a first input of the control unit (3). The substrate also comprises two frangible portions (6, 8), each one comprising a portion of the substrate (1) and a portion of the corresponding set of conductive tracks (4, 5), wherein each frangible portion (6, 8) comprises a breaking line (7) which has a mechanical resistance lower than the rest of the substrate (1).