Vehicular Lamp Light Source Unit Integral Molding
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Solution Overview
Problem
In vehicular lamps, ensuring high positional accuracy of the resin-molded unit of the heat sink is crucial to direct light emissions properly, preventing dazzling for other vehicles or pedestrians, which existing technologies have not adequately addressed.
Innovation Solution
The light source unit incorporates a socket housing with a metal heat sink and a resin-molded unit formed by integral molding, where the attachment and covered surfaces are pressed by mold portions, ensuring precise positioning and integration, and includes a connector for waterproofness and airtightness, with a concave or convex portion for stable engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the board is attached to the heat sink using conventional methods, then the light emitting element can be mounted, but the positional accuracy of the resin-molded unit is insufficient causing improper light direction
Solution Approach 1:
The mold is divided into multiple portions with specific functions: a first portion that presses the covered surface and a second portion that presses the attachment surface. This segmentation allows independent control of pressing forces on different surfaces, enabling high positional accuracy of the resin-molded unit while managing process complexity through functional division.
Solution Approach 2:
The heat sink is pressed by the mold portions before the resin material is injected into the mold. This preliminary pressing action pre-positions the heat sink and board in the correct spatial relationship, ensuring that when the resin solidifies, the resin-molded unit achieves high positional accuracy relative to the board attachment portion.
2Manufacturing precision
If the attachment surface and covered surface are pressed simultaneously during molding, then high positional accuracy is achieved, but the molding process becomes more complex
Solution Approach 1:
The molding process is segmented into distinct pressing actions: the first mold portion presses the covered surface while the second mold portion presses the attachment surface. This segmentation enables simultaneous pressing of multiple surfaces with independent force control, achieving high positional accuracy without requiring an overly complex integrated pressing mechanism.
Solution Approach 2:
The mold is designed with multi-functional portions that can perform multiple operations. The first mold portion not only presses the covered surface but also guides the resin material flow, while the second mold portion presses the attachment surface and maintains positioning. This multi-functionality reduces the need for additional separate components, easing manufacturing while maintaining precision.
3Temperature
If the resin-molded unit is made with high thermal conductivity, then heat dissipation is improved, but the material selection and manufacturing become more difficult
Solution Approach 1:
The socket housing is formed as a composite structure combining a metal heat sink with a resin-molded unit. The metal heat sink provides high thermal conductivity for effective heat dissipation from the light emitting element, while the resin material provides ease of molding and integration. This composite approach achieves superior heat dissipation without requiring the entire housing to be made from difficult-to-manufacture high-conductivity materials.
Solution Approach 2:
High thermal conductivity is localized to where it is most needed - the heat sink portion that contacts the light emitting element and board. The resin-molded unit portions that do not require high heat conduction can use standard, easier-to-manufacture materials. This local quality approach optimizes heat dissipation performance while maintaining ease of manufacture for non-critical components.
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 configuration ensures high positional accuracy of the resin-molded unit, proper light distribution, and effective heat dissipation, reducing the risk of dazzling and enhancing the vehicular lamp's performance and manufacturing efficiency.
Implementation Method 1
a resin-molded unit formed using a resin material and having thermal conductivity
Data Source
AI summary
A light source unit includes a board, a resin-molded unit formed using a resin material as a base material and having thermal conductivity, and a socket housing including a heat sink formed of a metal material, and a board attachment portion to which the board is attached and a covered surface which is covered with the resin-molded unit, wherein the resin-molded unit is formed with a holding hole communicating with the covered surface, and the heat sink and the resin-molded unit are formed by integral molding when a portion of the covered surface and a portion of the attachment surface are pressed by a portion of a mold inserted through the holding hole and another portion of the mold, respectively.