Automotive Lighting PCB Assembly With Elastic Interconnects

Solution Overview

Problem

Conventional methods for connecting PCBs in automotive lighting modules, such as wiring harnesses and rigid connectors, are costly, complex, and space-consuming, and fail to effectively dissipate heat while meeting thermal, optical, and electromagnetic compatibility (EMC) constraints.

Innovation Solution

The use of elastic connectors to interconnect PCBs, which are elastically deformable to establish connections between PCBs, eliminating the need for wiring harnesses and conventional connectors, and allowing for automated assembly, reduced complexity, and space optimization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wiring harnesses are used to connect PCBs, then electrical connection between PCBs is achieved, but space consumption increases, cost increases, and assembly complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the electrical connection function and mechanical support function into a single integrated PCB assembly structure. The first PCB assembly includes both the light sources and the electrical connection terminals, eliminating the need for separate wiring harnesses and connectors. This integration reduces assembly complexity while maintaining reliable electrical connections between components.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If wiring harnesses are used to connect PCBs, then electrical connection between PCBs is achieved, but space consumption increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidspace consumption

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent merges the electrical connection function and mechanical support function into a single integrated PCB assembly structure. The first PCB assembly includes both the light sources and the electrical connection terminals, eliminating the need for separate wiring harnesses and connectors. This integration reduces assembly complexity while maintaining reliable electrical connections between components.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If rigid connectors are used to connect PCBs, then mechanical and electrical connection is achieved, but positioning constraints increase and mechanical stress from vibrations increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmechanical stress from vibrations

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a dynamic connection approach where the second PCB assembly is positioned and connected to the first PCB assembly with flexibility to accommodate vibrations. The connection structure allows for slight movements and deformations without creating excessive mechanical stress, thereby maintaining connection reliability while resisting harmful vibrational effects.

Inventive Principle:

Principle #15Dynamics

4Reliability

If PCBs are connected with connectors, then electrical connection is achieved, but assembly labour increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidassembly labour

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the electrical connection function and mechanical support function into a single integrated PCB assembly structure. The first PCB assembly includes both the light sources and the electrical connection terminals, eliminating the need for separate wiring harnesses and connectors. This integration reduces assembly complexity while maintaining reliable electrical connections between components.

Inventive Principle:

Principle #5Merging (Combining)

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

Elastic connectors provide a reliable, cost-effective, and compact connection between PCBs, enhancing thermal performance, reducing assembly complexity, and improving EMC, while accommodating multiple PCBs in limited spaces.

Implementation Method 1

the second end (125) is adapted to be pressed against a contact zone (135) of, respectively, the second PCBA (110) or the first PCBA (105), by elastic deformation of the elastic connector (115)

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

a heat sink adapted to dissipate heat generated by the at least one light source

Methodology Applied

Scientific EffectHeat dissipation: Heat Sink

Data Source

PatentUS12565974B2Lighting module with interconnected PCB assemblies

Publication Date: 2026.03.03 VALEO VISION SA

AI summary

The present invention relates to an automotive lighting module able to perform front lighting functions. The lighting module includes at least a first Printed circuit board assembly (PCBA) mounted with at least one light source, a heat sink adapted to dissipate heat, at least a second PCBA, where at least the first PCBA is supported by the heat sink; and one or more reflectors. The first PCBA and the second PCBA are interconnected by an elastic connector which is elastically deformable. A first end of the elastic connector is fixed to the first PCBA, and a second end is adapted to be pressed against a contact zone of the second PCBA by elastic deformation of the elastic connector, to establish the connection between the first PCBA and the second PCBA.