Automotive Lighting Module Main Support Connector Design
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Solution Overview
Problem
The complexity of connecting multiple elements in automotive lighting devices, often located in hidden or disparate locations, leads to entangled wire harnesses and unreliable operation due to the difficulty in achieving proper electrical connections.
Innovation Solution
A lighting device design featuring a main support acting as a common bus connector for printed circuit boards, with expansion grooves to manage thermal strains and guide connectors for secure electrical connections, along with a bolt and oblong hole arrangement for adjustable positioning, simplifies the connection process and ensures reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wire harnesses are used to connect elements to the main connector, then electrical connections can be established, but the wire harnesses become entangled and trapped making connection difficult
Solution Approach 1:
The patent combines multiple wire harnesses into a single integrated cable assembly that routes through a dedicated channel in the housing. This merging approach eliminates entanglement between separate harnesses while maintaining all necessary electrical connections to the main connector.
Solution Approach 2:
The patent introduces a cable management channel as an intermediary structure that guides and organizes the wire harnesses. This channel acts as a mediator between the connectors and the housing, ensuring proper routing and preventing entanglement during assembly and operation.
2Reliability
If each printed circuit board has its own wire harness, then electrical supply and signals can be transmitted, but the lighting module is surrounded by multiple harnesses making correct connection difficult
Solution Approach 1:
The patent merges multiple individual wire harnesses into a single integrated cable assembly with multiple connectors. This reduces the number of separate harnesses surrounding the lighting module while maintaining all necessary electrical connections to each printed circuit board.
Solution Approach 2:
The patent creates a universal cable assembly that serves multiple functions simultaneously - providing electrical power, control signals, and data communication to multiple printed circuit boards through a single integrated structure, thereby simplifying the overall system architecture.
3Reliability
If the main support is rigidly fixed to all printed circuit boards, then stable electrical connection is achieved, but thermal expansion strains cause excessive stress in the main support
Solution Approach 1:
The patent changes the mechanical parameter of the main support from rigid to flexible by incorporating elastic elements. This allows the main support to accommodate thermal expansion and contraction of the printed circuit boards while maintaining stable electrical connections, thereby reducing stress on the main support structure.
Solution Approach 2:
The patent incorporates elastic elements in advance within the main support structure to cushion against thermal expansion strains. These pre-installed elastic components absorb the stresses generated during temperature variations, preventing excessive stress buildup in the main support before damage can occur.
4Manufacturing precision
If manufacturing tolerances are tight for printed circuit board positions, then precise electrical connections are achieved, but assembly becomes difficult due to tolerance variations
Solution Approach 1:
The patent introduces dynamic adjustment capabilities through movable components and elastic elements in the main support. This allows the system to adapt to manufacturing tolerance variations in printed circuit board positions during assembly, making the assembly process more forgiving and easier to perform while maintaining precise electrical connections.
Solution Approach 2:
The patent employs elastic elements that can deform within a certain range to accommodate position variations of printed circuit boards. This parameter change capability allows the main support to adjust to tolerance variations without requiring extremely tight manufacturing precision, thereby simplifying the assembly process.
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 design simplifies the connection process by providing a centralized main connector and adjustable support system, reducing the risk of entangled harnesses and ensuring consistent electrical supply to multiple printed circuit boards, thereby enhancing the reliability and ease of operation of automotive lighting modules.
Implementation Method 1
Since there may be many printed circuit boards in the lighting module, and each element may have different expansion strains, it is useful that the main support, which is attached to all of them, have some grooves to absorb the different expansion strains
Data Source
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AI summary
The invention is related to an automotive lighting module (10) comprising a main support (2), a first printed circuit board (3) and a second printed circuit board (4). The main support (2) comprises a main connector (21) and a first and second auxiliary connectors, which are in electrical connection with the main connector (21). The first printed circuit board (3) is fixed directly to the main support and is electrically connected to the first auxiliary connector. The second printed circuit board (4) is fixed directly to the main support and is electrically connected to the second auxiliary connector. When the main support (2) is connected to a main supply, it is suitable for providing electric supply and signals to the first and second printed circuit boards.