Carrier Plate Positioning for LED Reflector Alignment
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Solution Overview
Problem
Current assembly concepts for vehicle headlights with LED light sources face challenges in achieving precise positioning of reflectors due to significant tolerances throughout the mounting process, making optimal and legally compliant light image generation difficult.
Innovation Solution
A method involving attaching the light source to a support plate, measuring its position, attaching reference positions based on the light source's position, aligning and fixing a light-shaping body to these reference positions, and securing it to the support plate, thereby simplifying the exact positioning of the light source and light-shaping body relative to each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current assembly concepts are used (soldering LED to PCB, attaching PCB to heat sink, mounting reflector on heat sink), then the manufacturing process is simple and modular, but the positioning precision of the reflector relative to the LED light source deteriorates due to cumulative tolerances
Solution Approach 1:
The patent merges the LED mounting function and the positioning reference function into a single integrated component (the support plate). The support plate simultaneously provides mechanical support for the LED, establishes positioning references for the reflector, and maintains precise spatial relationships. This integration eliminates the need for separate positioning mechanisms and reduces the number of interfaces where tolerances could accumulate.
Solution Approach 2:
The support plate acts as an intermediary component between the LED light source and the reflector. It provides a stable reference framework that mediates the positioning relationship, allowing precise alignment without requiring direct measurement and adjustment between the LED and reflector. The support plate's integrated references serve as a mediator that translates the LED position into reflector positioning cues.
2Ease of manufacture
If multiple separate components are used (LED, PCB, heat sink, reflector), then the manufacturing and assembly process is simplified, but the tolerance chain becomes long and cumulative errors increase
Solution Approach 1:
The patent combines the mounting substrate and positioning reference system into a single integrated support plate. This merging reduces the number of separate components from four (LED, PCB, heat sink, reflector) to three (LED, support plate, reflector), eliminating two interfaces and their associated tolerances while maintaining ease of assembly.
Solution Approach 2:
The support plate is designed as a segmented structure with distinct functional zones: an LED mounting area, reference position indicators, and reflector mounting areas. This segmentation allows each zone to be optimized for its specific function while maintaining overall integration, enabling precise positioning without requiring complex monolithic structures.
3Reliability
If traditional mounting methods are used, then the assembly process is straightforward, but achieving legally compliant light distribution patterns becomes difficult due to positioning tolerances
Solution Approach 1:
The support plate provides self-aligning reference positions that guide the reflector into the correct position without requiring complex measurement tools or skilled adjustment. The integrated references on the support plate enable the assembly process to be self-correcting, ensuring legal compliance through built-in geometric constraints rather than relying on operator skill or post-assembly adjustment.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with a precision-machined support plate that provides fixed geometric references. Instead of using adjustable mounts, alignment screws, or measurement devices during assembly, the system uses precisely manufactured reference features on the support plate to define the correct reflector position, substituting mechanical complexity with precision manufacturing.
Data Source
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AI summary
The invention relates to a method for positioning a light-shaping body, for example, a reflector (1), relative to at least one light source (2), including the following steps: (a) attaching the at least one light source (2) to a carrier plate (3); (b) measuring the position of the at least one light source (2) on the carrier plate (3); attaching one or preferably a plurality of reference positions (4) to the carrier plate (3), the position of the at least one reference position (4) depending on the position of the at least one light source (2); (d) referencing, i.e. aligning the light-shaping body with the reference position(s) (4) on the carrier plate (3); and (e) securing the light-shaping body to the carrier plate (3) or with respect to the carrier plate (3).