Motor Vehicle LED Projection Unit Common Support Structure
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Solution Overview
Problem
Existing motor vehicle lighting and signaling devices with LED modules face challenges in heat dissipation, complex mechanical integration, and intricate electrical connections, which complicate production and performance optimization.
Innovation Solution
A unit comprising two optical modules with semiconductor light sources, a common control device, and a shared support structure that includes a printed circuit board for heat dissipation and flexible electrical connections, facilitating mechanical integration, heat management, and adjustment capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple LED modules are used to generate the beam, then the lighting performance is improved, but the heat generation increases significantly
Solution Approach 1:
The patent combines multiple LED modules onto a single common support structure that integrates both mechanical mounting and thermal management functions. The support structure merges the functions of structural support and heat dissipation into one unified component, allowing efficient heat evacuation from multiple LEDs while maintaining precise optical positioning.
2Ease of operation
If control device and current converter are added for LED control, then the lighting control capability is improved, but the device complexity increases
Solution Approach 1:
The control device and current converter are integrated into the common support structure alongside the LED modules. This merging of control electronics with the mechanical support reduces the number of separate components and simplifies the overall device architecture while maintaining full control capability over the LED array.
Solution Approach 2:
The common support structure serves multiple functions simultaneously: it provides mechanical mounting for LED modules, acts as a heat sink for thermal management, and integrates the control electronics. This multi-functionality reduces device complexity by eliminating the need for separate mounting brackets, heat sinks, and control housing.
3Manufacturing precision
If precise positioning of LED modules is implemented, then the optical performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The positioning and mounting functions are merged into the common support structure, which provides integrated mechanical features for precise LED module placement. The support structure incorporates positioning elements and mounting features that ensure accurate optical alignment during assembly, reducing the need for separate positioning mechanisms.
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 simplifies the production and integration of components, enhances heat dissipation, and allows for precise optical performance and beam adjustment, while ensuring reliable electrical connections and effective cooling, thus improving the operational efficiency and production complexity of motor vehicle lighting devices.
Implementation Method 1
a heat dissipation means arranged to dissipate at least part of the calories generated by the semiconductor light source
Implementation Method 2
The heat dissipation means may be formed by a radiator having a base and a plurality of cooling fins
Implementation Method 3
the heat dissipation means is in surface contact with the printed circuit board of the optical module. This ensures perfect transmission of the calories present on the printed circuit board to the heat dissipation means
Implementation Method 4
each of the modules comprises a light-emitting diode (hereafter led) forming the light source of the module
Implementation Method 5
The semiconductor light source(s) are light-emitting diodes, hereinafter referred to by the acronym LED
Implementation Method 6
By way of example, this optical projection device can be either at least one lens, or at least one reflector
Implementation Method 7
By way of example, this optical projection device can be either at least one lens, or at least one reflector, or a combination of a reflector and at least one lens
Data Source
AI summary
The invention relates to a projection unit 100 of a light beam intended to be installed in a motor vehicle projector 2, comprising: - at least two optical modules (20) each comprising at least one semiconductor light source (101) attached to an electrical connection support, and at least one optical projection device (23), - a control device (102) common to the two optical modules (20), - a common support (14) on which the two optical modules (20) and the control device (102) are attached, characterized in that the control device (102) comprises a printed circuit board (32), called primary, or a flexible printed circuit, which extends in a first plane which is transverse to a second extension plane of the electrical connection support of at least one of the optical modules (20).