Light-Source Module With Integrated Contact Positioning
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Solution Overview
Problem
Existing LED modules are not suitable for applications requiring precise light emission patterns and are difficult to replace without soldering, welding, or bonding, particularly in motor vehicle headlights where accurate alignment and reliable electrical and mechanical connections are necessary.
Innovation Solution
A light-source module with a defined light exit area and reference points for precise positioning, allowing easy insertion and replacement without soldering or welding, and ensuring reliable electrical and mechanical connections, along with effective heat dissipation using a thermally conductive body and adjustable reference points for accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If LED modules use conventional carrier plates for electrical connection and fastening, then electrical connection and mechanical fastening are achieved, but positioning precision relative to the optical axis deteriorates and replacement without soldering/welding becomes difficult
Solution Approach 1:
The patent combines the electrical connection function and mechanical positioning function into a single integrated contact element. The contact element serves both as an electrical conductor and as a mechanical reference point that defines the module's position relative to the optical axis, eliminating the need for separate positioning mechanisms and soldering operations.
Solution Approach 2:
The contact element automatically performs dual functions: establishing electrical connection and defining mechanical position simultaneously. When the module is inserted, the contact element self-aligns to provide both electrical conductivity and precise positioning without requiring external alignment procedures or additional fastening steps.
2Ease of operation
If LED modules are designed for easy replacement without soldering, then ease of operation improves, but reliability of electrical and mechanical connections deteriorates
Solution Approach 1:
The patent separates the connection function into distinct contact elements that can be individually engaged and disengaged. Each contact element is designed as an independent component that provides both electrical connection and mechanical positioning, allowing the module to be replaced as a single unit without compromising connection integrity.
Solution Approach 2:
The patent replaces traditional mechanical fastening systems (screws, clips, soldering) with an electrical contact-based positioning system. The contact elements themselves define the mechanical position through their geometric arrangement, substituting complex mechanical fastening mechanisms with a simpler electrical contact interface that inherently provides both connection and positioning.
3Manufacturing precision
If reference points are made adjustable for precise alignment, then positioning precision improves, but device complexity increases
Solution Approach 1:
The contact elements automatically define the reference points for alignment through their fixed geometric arrangement on the carrier plate. The system self-aligns during insertion without requiring adjustable mechanisms, as the contact elements' positions inherently establish the correct orientation and location relative to the optical axis.
Solution Approach 2:
The patent uses the fixed geometric pattern of contact elements as a template or copy of the desired optical arrangement. The contact elements replicate the spatial relationships needed for precise LED positioning, transferring the alignment information from the electrical connection points to the optical element positions without requiring separate adjustment 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
The solution enables precise light emission patterns with lower tolerance, easy module replacement, and reliable connections in motor vehicle headlights, ensuring accurate alignment and efficient heat dissipation, even under severe vibration conditions.
Implementation Method 1
a body (2), made of a material having high thermal conductivity, by which heat emitted by the light-emitting elements (3) is dissipated
Data Source
AI summary
A light-source module is described having at least one light-emitting element (3) such as, in particular, LEDs, light guides, collimator elements or lens elements, which together form a light exit area, as also is a holder for a module of this in the form of an LED module, system, such as in particular a motor vehicle headlight or a lighting or projecting means, that is intended to have a given light emission pattern. For this purpose, the module is able to be positioned relative to at least one reference plane of the optical system and, at the same time, is able to be replaced easily without soldered, bonded or welded connections being required.