Vehicle Headlight Component Housing Thermal and Mechanical Design
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Solution Overview
Problem
Current vehicle headlight systems face challenges in maintaining mechanical stability and easy maintenance while preventing mechanical stresses and temperature-related issues from affecting the optical, electrical, and thermal components, especially during assembly and operation.
Innovation Solution
A component housing design featuring a housing shell, cover, printed circuit boards, spacers, and connecting elements that securely attach and cool the electronic component, allowing for easy access and maintenance, while dissipating mechanical loads and ensuring precise alignment with the imaging optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the electronic component is securely mounted in the component housing, then mechanical stability is improved, but mechanical stresses may affect the optical and electrical connections
Solution Approach 1:
The mounting structure is divided into separate functional elements: the component housing provides mechanical support while the optical component is mounted in a way that isolates it from housing stresses. The electrical connections are routed and supported independently to prevent stress transmission.
Solution Approach 2:
An intermediary mounting structure or stress-isolating interface is introduced between the electronic component and the housing to decouple mechanical stresses. This allows the component to be securely mounted while preventing stress transmission to sensitive optical and electrical connections.
2Ease of operation
If the housing is designed for easy maintenance and access, then ease of operation is improved, but mechanical protection may be reduced
Solution Approach 1:
The housing is segmented into removable sections or access panels that can be easily opened for maintenance while the main structure remains intact to provide mechanical protection. The optical component can be accessed through a specific opening without compromising the overall housing integrity.
Solution Approach 2:
The housing incorporates dynamic access mechanisms such as removable panels or hinged sections that allow easy maintenance access when needed, while maintaining a closed, protective structure during normal operation. This provides both ease of maintenance and mechanical protection at different times.
3Temperature
If thermal management is enhanced for the electronic component, then temperature control is improved, but device complexity increases
Solution Approach 1:
The housing structure is combined with thermal management functions by integrating heat dissipation features directly into the housing walls or mounting surfaces. The housing serves both as mechanical protection and as a thermal pathway, eliminating the need for separate complex cooling systems.
Solution Approach 2:
The housing structure itself provides thermal management through its material properties and geometry, such as heat-conductive walls or integrated heat sinks, without requiring additional active cooling components. The structure serves its own thermal regulation needs.
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
The solution provides a robust and stress-free assembly and maintenance environment, ensuring the optical and thermal functionality of the headlight components, enhancing durability and performance by minimizing mechanical and thermal stresses.
Implementation Method 1
the first spacer can be designed to be resilient, that is, to be elastically deformable
Implementation Method 2
a heat sink that is arranged on the thermal surface
Implementation Method 3
The inlet and the outlet of the cooling line are arranged in the inlet opening and in the outlet opening
Data Source
Figure 1~2
Figure 3~10
Figure 4~11
AI summary
The invention relates to a vehicle headlight comprising at least one light source, at least one projection optical system, and an electronic component (1) with an operative optical surface on a front face, an active thermal surface, and electric contacts. Furthermore, a component housing (110) which is made of a housing shell (120) and a housing cover (150) contains a first printed circuit board (130) and at least one first spacer (160). The component housing (110) at least partly receives the electronic component (1). The housing shell (120) comprises an assembly position for the electronic component (1) and a component opening (121) which is located in the region of the assembly position, in which the electronic component (1) is arranged, and by means of which the active optical surface of the electronic component (1) can be accessed. The electronic component (1) can be connected to the first printed circuit board (130) via the electric contacts of the electronic component. The housing shell (120) can be closed by the housing cover (150). The at least one spacer (160) is arranged between a paired support point and the housing cover (150), wherein the support point lies on the first printed circuit board (130), and at least one connection element is provided for producing a connection between the housing cover (150) and the housing shell (120), said connection element being introducible preferably along an axis which runs transversely to the printed circuit board (130).