LED Mounting Substrate Terminal Layout for Compact Vehicle Headlamps
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Solution Overview
Problem
In vehicle light fixtures, particularly high-luminance headlamps, the dense mounting of LEDs on a substrate requires numerous terminals, leading to increased space for terminals and wires, hindering downsizing and efficient assembly due to the need for precise spacing, which complicates the miniaturization of both light-emitting devices and modules.
Innovation Solution
A light-emitting device with a mounting substrate featuring first and second terminals on opposite surfaces, allowing for individual control of LEDs and reduced terminal layout area, combined with a connector system that clamps the substrate's end portion to secure and connect the terminals, eliminating the need for wire bonding and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If many terminals are provided on the mounting substrate to individually control light-emitting elements, then individual control capability is improved, but the area occupied by terminals increases
Solution Approach 1:
The patent transitions from a two-dimensional terminal arrangement on a single surface to a three-dimensional configuration where terminals are distributed across both the first and second surfaces of the mounting substrate. This spatial redistribution allows individual control capability to be maintained while reducing the footprint area occupied by terminals on any single surface.
2Adaptability or versatility
If many terminals are provided on the mounting substrate, then individual control capability is improved, but the light-emitting device size increases
Solution Approach 1:
By utilizing both surfaces of the mounting substrate for terminal placement, the patent reduces the horizontal spread required for terminals, thereby compacting the overall light-emitting device dimensions while preserving individual control functionality for each light-emitting element.
3Reliability
If wires are used to connect terminals to the circuit board, then electrical connection is achieved, but the distance between wires must be ensured to avoid interference, which increases module size
Solution Approach 1:
The patent redistributes terminals across both surfaces of the mounting substrate, which optimizes wire routing paths and reduces the horizontal spacing requirements between adjacent wires. This three-dimensional terminal arrangement allows for more compact wire bundling and connection to the circuit board, thereby reducing the overall module volume while maintaining reliable electrical connections.
Data Source
AI summary
A light-emitting device includes a mounting substrate having a first surface and a second surface opposite to the first surface, the mounting substrate having a first end portion at an end of the mounting substrate; light-emitting elements mounted on the first surface of the mounting substrate other than the first end portion; first terminals provided on the first surface at the first end portion of the mounting substrate and connected to the light-emitting elements; and second terminals provided on the second surface at the first end portion of the mounting substrate and connected to the light-emitting elements.