Vehicle LED Driver Module Integrated Water Tightness

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Solution Overview

Problem

Conventional LED driver modules for vehicles require separate cases for water tightness, increasing complexity and costs due to the need for a case sealing process and inspection of water tightness.

Innovation Solution

An LED driver module design that integrates a connector part, board part, seating part, and cover part within the lamp housing, eliminating the need for a separate case for water tightness, and incorporating guide members and misassembling prevention structures to simplify assembly and reduce costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate case structure is used for water tightness, then water tightness is ensured, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvewater tightnessVSAvoidcase structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the protective case structure with the lamp housing by integrating the LED driver module directly into the lamp housing cavity. The lamp housing serves dual purposes: as the structural housing for the LED lamp and as the protective enclosure for the LED driver module, eliminating the need for a separate case while maintaining water tightness through the lamp housing's inherent sealed structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lamp housing is designed to serve multiple functions: it houses the LED light source, provides structural support, ensures water tightness for the entire assembly, and acts as the protective enclosure for the LED driver module. This multi-functional design eliminates the need for dedicated separate cases for the driver module.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate case with sealing process is used, then water tightness is ensured, but manufacturing process complexity and cost increase

Engineering Contradiction:

Improvewater tightnessVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the sealing function into the lamp housing's existing sealed structure rather than requiring a separate case sealing process. The lamp housing is designed with integrated sealing features that protect both the LED light source and the LED driver module simultaneously, reducing the number of sealing operations required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the LED driver module from its traditional separate enclosed case and relocates it directly into the lamp housing cavity. This eliminates the need for a separate case assembly and its associated sealing process, while the lamp housing's existing sealed structure continues to provide water tightness for the integrated module.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If water tightness inspection process is added, then water tightness quality is ensured, but manufacturing time and cost increase

Engineering Contradiction:

Improvewater tightness qualityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the water tightness protection function into the lamp housing's existing sealed structure that already protects the LED light source. Since the LED driver module is integrated into this pre-sealed housing, the same sealing structure provides protection for both components, eliminating the need for separate water tightness inspection processes for the driver module.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If separate case and sealing process are used, then water tightness is ensured, but production cost increases

Engineering Contradiction:

Improvewater tightnessVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the protective enclosure function with the lamp housing, eliminating the need for a separate case. The lamp housing serves as both the structural housing for the LED lamp and the protective enclosure for the LED driver module, reducing component count and assembly costs while maintaining water tightness through the housing's integrated sealed structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the LED driver module from its traditional separate enclosed case and integrates it directly into the lamp housing. This eliminates the need for manufacturing and assembling a separate case, reducing material costs, manufacturing complexity, and production expenses while the lamp housing's existing sealed structure continues to provide water tightness.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11415307B1LED driver module and vehicle including the same

Publication Date: 2022.08.16 HYUNDAI MOBIS CO LTD

AI summary

Disclosed are an LED driver module and a vehicle including the same. An LED driver module coupled to a lamp housing of a vehicle includes a connector part coupled to an interior of the lamp housing of the vehicle, a board part, of which a distal end in a first direction contacts the connector part, the first direction being a direction that faces an inside of the lamp housing from an outside thereof, a seating part, on which the board part is seated, and of which a distal end in the first direction contacts the connector part, and a cover part coupled to a side of the seating part in a second direction that is an opposite direction to the first direction, and covering the board part and the seating part from the outside of the lamp housing.