Vehicle Lamp PCB Positioning With Spring-Loaded Reflector Mount
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Solution Overview
Problem
Existing illumination devices for vehicles using semiconductor light sources face challenges in precisely positioning the light emitting assembly relative to optical devices due to component variations and tolerances, leading to deviations in light cone shape and intensity, and require complex, time-consuming assembly processes.
Innovation Solution
A bracket with springs and a positioning pin system is used to securely attach the light emitting assembly to the optical device, ensuring precise positioning through perpendicular pretension forces and a screw fixation, allowing for easy assembly and reducing component variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If semiconductor light sources are used with directional light radiation, then electrical power consumption is reduced and light efficiency is improved, but positioning precision between the light source and optical devices becomes critical and difficult to maintain due to component tolerances
Solution Approach 1:
The patent applies preliminary action by providing positioning pins and corresponding positioning holes that are pre-configured in the optical device and light emitting assembly respectively. These positioning features are prepared in advance during manufacturing, allowing the light emitting assembly to be precisely positioned and fixed to the optical device before final assembly, thereby maintaining positioning precision despite component tolerances and directional light radiation requirements
2Manufacturing precision
If traditional light bulbs are used with omnidirectional light radiation, then positioning is more tolerant, but electrical power consumption is higher and light efficiency is lower
Solution Approach 1:
The patent applies parameter changes by transitioning from omnidirectional light radiation (traditional bulbs) to directional light radiation (semiconductor light sources). This change in the light radiation parameter allows for reduced electrical power consumption and improved light efficiency, while the positioning precision is maintained through the specialized positioning pin and hole system that compensates for the stricter positioning requirements of directional light sources
3Adaptability or versatility
If multiple separate components are used in the illumination device, then assembly flexibility is improved, but assembly time and complexity increase
Solution Approach 1:
The patent applies merging by integrating the positioning pins into the optical device structure and the positioning holes into the light emitting assembly structure. This integration allows the components to be pre-configured with their positioning features during manufacturing, enabling faster assembly where the light emitting assembly can be directly positioned and fixed to the optical device without requiring separate positioning steps or additional components, thereby reducing assembly time while maintaining flexibility
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 achieves a reliable, precise, and compact positioning of the light emitting assembly, maintaining consistent light cone shape and intensity while simplifying the assembly process.
Implementation Method 1
a first spring (224) and a second spring (225) for exerting a pretension force on the dome (310) of the optical device (300), the springs being formed out of the bracket (220) and arranged in a space between the legs (222) and the support (221), wherein the first spring (224) and the second spring (225) face in perpendicular directions
Implementation Method 2
the printed circuit board (210) comprises a positioning hole (213) for receiving the positioning pin (330) and to position the light emitting assembly (200) relative to the optical device (300)
Implementation Method 3
allowing for easy assembly and reducing component variations
Data Source
Figure 1
Figure 2~3
Figure 4a
AI summary
Illumination device (1) for a vehicle, comprising an optical device (3), in particular a reflector (300), with a dome (310) and with a positioning pin (330) and further comprising a light emitting assembly (200) with a printed circuit board (210) and a semiconductor light source (211), in particular a light emitting diode (212), and the light emitting assembly (200) comprises a bracket (220) with at least one spring (224, 225) for exerting a pretension force on the dome (310) of the optical device (3), and the printed circuit board (210) comprises a positioning hole (213) for receiving the positioning pin (330) and to position the light emitting assembly (200) relative to the optical device (3).