Lead Frame Electrical Connection for Remote LED Placement
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Solution Overview
Problem
Existing systems for electrically connecting light sources, such as LEDs, to power systems in motorized vehicles require complex structures with specific heat-dissipating components and additional shaping operations, increasing design and production costs while complicating the lighting module's structure.
Innovation Solution
A simplified system using a lead frame with integral conductive tracks that can be electrically connected to a power supply, allowing the light source to be placed remotely, eliminating the need for specific heat-dissipating components and simplifying the structure by using a resistive circuit or converter for heat dissipation and voltage conversion, along with a separate heat-dissipating means for the light source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive board with cavities is used to place lighting devices, then the lighting devices can be connected to the power supply, but additional forming operations are required and the structure becomes complex
Solution Approach 1:
The patent combines the conductive board and heat-dissipating holder into a single integrated component. The conductive board serves dual functions as both the electrical connection substrate and the heat dissipation structure, eliminating the need for separate cavities and reducing manufacturing complexity while maintaining reliable electrical connections to the lighting devices
Solution Approach 2:
The conductive board is designed to perform multiple functions simultaneously: providing electrical connections through integrated circuits, dissipating heat from the lighting devices, and serving as a mounting structure. This multi-functionality eliminates the need for separate specialized components, reducing overall device complexity
2Temperature
If a heat-dissipating holder is used to preserve luminous efficacy, then heat can be dissipated effectively, but the structure of the lighting module is complicated
Solution Approach 1:
The heat-dissipating function is merged into the conductive board itself. The board's inherent thermal conductivity is utilized to dissipate heat from the lighting devices, eliminating the need for a separate heat-dissipating holder and simplifying the overall module structure while maintaining effective temperature control
Solution Approach 2:
The conductive board is designed as a multi-functional component that simultaneously provides electrical connections, structural support, and heat dissipation. By integrating these functions into a single component, the patent reduces the number of parts and simplifies the lighting module structure while ensuring effective heat management
3Ease of manufacture
If the light source is placed close to the lead frame, then electrical connection is simplified, but the lead frame is exposed to heat from the light source
Solution Approach 1:
The patent introduces an intermediary flexible connecting means (such as a flexible circuit or wire harness) between the lead frame and the light source. This intermediary allows electrical connection while providing thermal isolation, preventing heat from the light source from damaging the lead frame while maintaining ease of electrical connection
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 reduces design and production costs by simplifying the structure, minimizing heat exposure to the lead frame, and allowing efficient heat dissipation through a separate heat-dissipating means, while maintaining effective power supply and electromagnetic interference protection.
Implementation Method 1
a lead frame able to be electrically connected to a system for supplying electrical power, the lead frame including at least one connecting terminal
Implementation Method 2
the lead frame includes a first means for dissipating heat allowing the heat generated by the lead frame to be dissipated
Data Source
AI summary
A system for electrically connecting at least one light source to a system for supplying electrical power, wherein the connecting system comprises a lead frame able to be electrically connected to a system for supplying electrical power, the lead frame including at least one connecting terminal and at least one connecting means allowing the connecting terminal of the lead frame to be electrically connected to the light source, the connecting terminal and the connecting means being able to electrically connect the light source to the lead frame, thereby allowing the light source to be placed away from the lead frame.