Headlight Complex Light Source Interface Shift
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Solution Overview
Problem
The existing headlight systems with semiconductor light sources face challenges in replacing LED light sources due to difficulties in providing a detachable thermal connection and the risk of misaligning the optical system, leading to potential dazzling of oncoming traffic and high repair costs, especially in vehicles where the entire headlight needs to be replaced upon failure.
Innovation Solution
The design features a complex light source with a semiconductor light source and heat sink, where the interface between the light source and the optical system is shifted, allowing for non-destructive and easy replacement by pivoting the light module, which remains stationary during maintenance, thereby avoiding positional inaccuracies that affect light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the semiconductor light source is thermally firmly coupled to the heat sink using thermally conductive adhesive or paste, then heat dissipation is effective, but the connection becomes difficult to detach for replacement
Solution Approach 1:
The patent divides the light source assembly into separable modules: the semiconductor light source is mounted on a circuit board that is attached to the heat sink, but the entire assembly can be detached as a unit. This segmentation allows effective thermal coupling during operation while enabling easy replacement when needed.
Solution Approach 2:
The circuit board serves as an intermediary element between the semiconductor light source and the heat sink. It provides both thermal conduction path for heat dissipation and mechanical support for the light source, while the overall assembly can be detached from the headlight housing through electrical and mechanical interfaces.
2Ease of repair
If the light source is replaced, then repair is possible, but the optical system may become misaligned causing dazzling of oncoming traffic
Solution Approach 1:
The patent incorporates preliminary alignment features during manufacturing, such as precision-machined mounting surfaces,定位 holes, and mechanical stops on the heat sink and headlight housing. These pre-established reference features ensure that when the light source assembly is reinstalled, it automatically returns to the correct optical alignment position without requiring complex adjustment procedures.
Solution Approach 2:
The patent replaces complex mechanical adjustment systems with precision-machined fixed positioning features. Instead of requiring manual alignment of the light source after replacement, the design uses precisely manufactured mechanical interfaces (mounting surfaces,定位 structures) that automatically ensure correct optical alignment when components are assembled.
3Manufacturing precision
If the entire headlight is replaced upon light source failure, then proper alignment is maintained, but repair costs become disproportionately high for lower-value vehicles
Solution Approach 1:
The patent segments the headlight system into replaceable modules (light source, circuit board, heat sink assembly) and a permanent housing containing the optical system. This allows only the light source module to be replaced while keeping the expensive optical housing, thereby reducing repair costs while maintaining alignment through precision-machined interfaces.
Solution Approach 2:
The patent enables selective replacement of the light source assembly (which may be damaged or degraded) while recovering and retaining the valuable optical housing and lens components. The precision-machined interfaces ensure that the recovered housing maintains its optical alignment properties when the new light source module is installed.
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 solution enables easy replacement of semiconductor light sources without misaligning the optical system, reducing repair costs and ensuring consistent light distribution quality, as the interface shift minimizes positional inaccuracies between the light exit surfaces and the optical system, maintaining the headlight's performance.
Implementation Method 1
a heat sink that contacts the semiconductor light source in thermal coupling
Implementation Method 2
an optical system that collects and directs light from the semiconductor light source
Data Source
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AI summary
A headlight for a motor vehicle having a housing, a semiconductor light source, a cooling body, an optical system which collects and directs light of the semiconductor source, a securing frame which is mechanically connected to the housing and which holds the semiconductor light source with the cooling body and the optical system in the housing, and having an interface between the first part which forms a complex light source and comprises at least the semiconductor light source and the cooling body, and a second part which comprises at least the holder, wherein the first part is connected to the second part at the interface so that it can be separated without destruction. The headlight is defined by the fact that the first part which forms the complex light source has, in addition to the semiconductor light source and the cooling body, at least one optical system which collects and directs a light of the semiconductor light source.