Automotive Lighting PCB Daisy-Chain Connectors for Reduced Wiring
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Solution Overview
Problem
The assembly of automotive light modules is complex due to the need for precise electrical interconnections in a confined space, and reducing wire harnesses while maintaining functionality is challenging, especially when connecting multiple printed circuit boards with light sources.
Innovation Solution
An automotive lighting device using a daisy-chain connection with multiple substrates and connectors, each with inputs and outputs, and an independent electric circuit for connector position assurance, allowing for efficient power and control signal transmission without excessive wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple printed circuit boards are connected with separate wire harnesses to maintain functionality, then reliability of electrical connection is improved, but device complexity and wiring quantity increase
Solution Approach 1:
The patent combines multiple separate wire harnesses into a single integrated wire harness that connects the main printed circuit board to multiple secondary printed circuit boards. This merging approach reduces the total quantity of cables and connectors while maintaining all necessary electrical connections, thereby reducing device complexity without sacrificing connection reliability.
Solution Approach 2:
The integrated wire harness is designed to serve multiple functions simultaneously - it provides power supply, control signals, and communication channels to multiple secondary substrates through a unified structure. This multi-functionality eliminates the need for separate dedicated harnesses for each substrate, reducing overall wiring complexity while ensuring reliable connections.
2Adaptability or versatility
If the number of pins is multiplied or splices are created in harnesses to connect driver board to multiple light source boards, then functionality is maintained, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
The wire harness is segmented into multiple branches, each connecting to a specific secondary printed circuit board. This segmentation allows each branch to be independently routed and connected, reducing the complexity of any single connection point and minimizing the need for complex splices or multi-pin connectors at any single location.
Solution Approach 2:
The integrated wire harness acts as an intermediary structure that consolidates multiple connection paths into a single manageable component. Rather than creating multiple separate connections between the driver board and each light source board, the harness mediates all connections through its organized internal structure, simplifying assembly and improving manufacturing precision.
3Volume of moving object
If operators perform electrical interconnections without direct visual contact due to limited space, then assembly compactness is improved, but ease of operation deteriorates
Solution Approach 1:
The wire harness is pre-assembled and pre-configured with all necessary connections before installation into the compact module. This preliminary action allows operators to simply plug in the pre-prepared harness rather than performing complex manual wiring in the confined space, significantly improving ease of operation while maintaining compact dimensions.
Solution Approach 2:
The integrated wire harness design incorporates self-aligning features and standardized connectors that enable the connection to be made without precise manual positioning. The harness structure itself guides the connection process, reducing the skill level and visual contact required during assembly, thereby improving ease of operation in compact spaces.
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The present invention refers to an automotive luminous device (10) a main substrate (1) with a driver (2) and a main connector (3) coupled to the edge portion (11) of the main substrate (1), the main connector (3) comprising at least four electrical inputs (31) and four electrical outputs (32), each electrical input (31) being configured to receive power supply and control signals and being electrically coupled to an electric track of the main substrate (1) and each electrical output (32) being electrically coupled to an electric track of the main substrate (1). The device (10) further comprises secondary substrates (4, 6), comprising light sources (9) to be commanded by the driver (2). The device (10) further comprises secondary connectors (5, 7) coupled to the edge portion of the corresponding secondary substrate, the each secondary connector comprising at least four inputs (51, 71), each input being connected by wire with one output (32, 52) of the previous connector (3, 5), and four outputs (52).