Vehicle Lamp Heat Sink With Integrated Coupling Protrusions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vehicle lamp manufacturing processes are complicated and costly due to the need for additional coupling parts and heat-based assembly methods.
Innovation Solution
A vehicle lamp design that couples a light source unit to a metal plate acting as a heat sink, which is then supported by a fixing plate using a simple mechanical structure without additional coupling parts or heat, utilizing a metal plate with high thermal conductivity and a coupling mechanism involving protrusions and grooves for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic bracket with rib is used to couple components, then the components can be fixed together, but additional coupling parts are required and heat-based processes are needed
Solution Approach 1:
The patent integrates the coupling function directly into the metal plate by forming coupling protrusions and coupling grooves as integral parts of the metal plate structure. This merging eliminates the need for separate plastic bracket components while maintaining reliable coupling between the light source unit, heat sink, and PCB.
Solution Approach 2:
The metal plate serves multiple functions simultaneously: it acts as a heat dissipation component (heat sink), a structural support element, and a coupling mechanism through its integrated protrusions and grooves. This multi-functionality replaces the specialized plastic bracket designed solely for coupling purposes.
2Ease of manufacture
If a plastic bracket is used for coupling, then components can be assembled, but manufacturing costs increase due to additional parts and heat processes
Solution Approach 1:
By combining the coupling function into the metal plate structure itself, the patent reduces the total number of parts from multiple components (plastic bracket, metal plate, heat sink, PCB) to an integrated assembly where the metal plate performs both structural and coupling roles.
Solution Approach 2:
The patent extracts the coupling function from the separate plastic bracket and relocates it directly to the metal plate. This extraction eliminates the need for the plastic bracket while preserving the essential coupling capability between components.
3Strength
If heat is used to melt the rib for coupling, then the components are fixed securely, but the manufacturing process becomes complicated
Solution Approach 1:
The patent replaces the thermal coupling process (heating and melting) with a mechanical coupling system using protrusions and grooves. This mechanical interface achieves secure fixation through geometric interlocking without requiring heat application equipment or thermal processing steps.
Solution Approach 2:
The patent removes the heat-based coupling process entirely from the manufacturing sequence. By extracting the thermal fixation method and replacing it with a cold-formed mechanical coupling system, the manufacturing process is simplified while maintaining coupling strength.
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 design simplifies the assembly process, reduces manufacturing costs, and enhances heat dissipation performance, resulting in a more efficient and cost-effective vehicle lamp production.
Implementation Method 1
a metal plate onto which the light source unit is mounted on a surface thereof dissipates heat generated from the light source unit
Data Source
AI summary
A vehicle lamp that includes components structured to be simply coupled to each other. The vehicle lamp includes a light source unit that emits light, a metal plate onto which the light source unit is mounted on a surface thereof and dissipates heat generated from the light source unit, and a fixing plate that is coupled to the metal plate and supports the metal plate. A coupling protrusion is formed on any one of the metal plate and the fixing plate, a coupling groove coupled to the coupling protrusion is formed in the other one of the metal plate and the fixing plate, and the metal plate includes two or more walls that face each other and a connection surface which connects the walls.