Inclined LED Mounting Surface for Automotive Lighting
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Solution Overview
Problem
Existing lighting modules, particularly in automotive applications, lack efficient optical properties and ease of exchangeability, with existing solutions requiring complex disconnection of heat sink parts for LED module replacement.
Innovation Solution
A lighting module design featuring a heat sink with a protrusion portion angled 5-45° for optimal LED placement, integrated electrical plug connectors within the heat sink cavity, and alignment protrusions for precise positioning, allowing for efficient light emission and easy module replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED elements are mounted on a flat mounting surface perpendicular to the forward direction, then the structure is simple and manufacturing is easy, but the optical properties are inefficient and light emission direction is limited
Solution Approach 1:
The patent applies asymmetry by designing the mounting surface with a specific inclination angle (5-45 degrees) relative to the forward direction, creating an asymmetric geometry that optimizes light emission direction. This inclined mounting surface allows light to be directed more effectively toward the reflector, improving illumination efficiency without requiring complex additional optical components.
Solution Approach 2:
The patent introduces a new dimensional parameter by tilting the mounting surface at an angle rather than keeping it perpendicular to the forward direction. This angular dimension allows the light emission to be redirected optimally toward the reflector, transforming the light distribution pattern and improving overall optical efficiency.
2Ease of operation
If LED elements are fixed within a non-exchangeable lighting system, then the structure is stable and reliable, but replacement and maintenance are difficult
Solution Approach 1:
The patent applies segmentation by dividing the lighting system into an exchangeable lighting module and a fixed reflector assembly. The lighting module containing the LED elements and heat sink can be independently removed and replaced, while the reflector remains in place. This modular segmentation enables easy maintenance and replacement while maintaining system reliability through standardized connection interfaces.
Solution Approach 2:
The patent introduces dynamic exchangeability by designing the lighting module with removable mechanical coupling and electrical plug connectors. The module can be dynamically inserted and removed from the reflector assembly, allowing for easy replacement while maintaining reliable electrical and mechanical connections during operation.
3Volume of moving object
If the electrical plug connector is mounted externally on the heat sink, then the electrical connection is accessible, but the module dimensions increase and compactness is reduced
Solution Approach 1:
The patent applies the nesting principle by integrating the electrical plug connector within a cavity of the heat sink body. The connector is nested inside the heat sink structure rather than being mounted externally, which maintains compact module dimensions while still providing accessible electrical connections through the cavity opening.
Solution Approach 2:
The patent merges the electrical plug connector with the heat sink structure by providing the connector within a cavity of the heat sink body. This integration combines two previously separate components (connector and heat sink) into a unified structure, reducing overall module volume while maintaining both thermal management and electrical connection functions.
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 enhances optical properties by directing light emissions effectively and facilitates easy replacement of lighting modules within automotive systems, ensuring precise alignment and maintaining compact module dimensions.
Implementation Method 1
The heat sink should be made out of a material with good heat conduction, preferably metal, in particular comprising aluminum and/or copper
Implementation Method 2
heat fins may be provided on the body portion to dissipate heat
Data Source
AI summary
A lighting module comprises a heat sink with a body portion and a protrusion portion protruding from the body portion into a forward direction. An LED element is mounted on a mounting surface of the protrusion portion. The mounting surface is arranged facing partially backwards and forming an angle of 5-45° to the forward direction. An electrical plug connector is provided within the body portion's cavity and is electrically connected to the LED element. In the lighting system, a reflector assembly comprises a concave reflector with an inner reflector space. A lighting module is arranged such that its protrusion portion projects into the inner reflector space. Light emitted from the LED element is reflected by the reflector. The body portion is arranged outside of the reflector space. The lighting module may be replaced by separating the lighting module from the reflector assembly and providing a new lighting module.