Modular Light Source Assembly for Vehicle Lamps
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Solution Overview
Problem
The high costs and resource consumption associated with designing and manufacturing custom molds for vehicle lamp heat sinks and back covers, as well as the high replacement costs due to potential LED module damage, necessitate a standardized LED support structure for vehicle lamps.
Innovation Solution
A light source assembly comprising detachably connected modules with a standardized heat sink structure, featuring a frame part with couplings for easy assembly and a heat radiation plate for efficient heat dissipation, allowing for modular configuration to accommodate various vehicle lamp designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom molds are designed and manufactured for each vehicle model's heat sink and back cover, then the heat dissipation and structural requirements are met, but the molding costs increase and resource consumption increases
Solution Approach 1:
The patent applies universality by designing a standardized heat sink module that can be commonly used across different vehicle models. The module includes a heat sink body with a standardized installation structure that can accommodate various LED light source assemblies. This allows the same heat sink design to serve multiple vehicle lamp applications, eliminating the need for custom molds for each vehicle model while still meeting heat dissipation requirements through optimized fin structures and material selection.
Solution Approach 2:
The patent segments the lamp assembly into modular components: a standardized heat sink module, LED light source assemblies, and a lamp housing. The heat sink module is designed as a separate, reusable component that can be independently manufactured and assembled. This segmentation allows the heat sink to be produced once and reused across multiple vehicle models, reducing molding costs while maintaining thermal performance.
2Adaptability or versatility
If custom molds are designed and manufactured for each vehicle model, then the specific design requirements are met, but large amounts of resources such as manpower and materials are consumed
Solution Approach 1:
The standardized heat sink module serves multiple vehicle models and lamp designs, reducing the need for repeated mold manufacturing. The module's universal installation interface allows it to be adapted to different lamp configurations through software or electrical connections rather than requiring new physical molds, thereby conserving materials and manpower.
Solution Approach 2:
While the heat sink module is standardized, the patent allows for local customization in the LED light source assemblies and lamp housing to meet specific vehicle model requirements. This means resources are concentrated on designing the critical thermal management component once, while allowing flexibility in non-critical areas, thereby optimizing resource allocation.
3Reliability
If a mold is obtained through custom design, then the specific vehicle model's requirements are met, but the mold needs to be stored and maintained until the vehicle model is discontinued
Solution Approach 1:
The standardized heat sink module can be used across multiple vehicle models and generations, eliminating the need for long-term storage and maintenance of dedicated molds. The module's universal design allows it to remain in production use for extended periods, serving multiple vehicle platforms and reducing the idle time associated with mold storage.
4Reliability
If the exterior of an LED or LED module is damaged during manufacturing or assembly, then replacement is necessary, but high replacement costs and large amounts of raw material loss occur
Solution Approach 1:
The patent segments the LED light source assembly as a separate, replaceable module that can be independently replaced without replacing the entire lamp assembly or heat sink. The standardized interface allows damaged LED modules to be quickly swapped out, reducing material waste and replacement costs compared to replacing entire custom-molded assemblies.
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 solution reduces manufacturing and investment costs by enabling the use of standardized components, simplifying assembly, and minimizing material waste while maintaining flexibility in accommodating different vehicle lamp designs through modular connections.
Implementation Method 1
a heat radiation plate for efficient heat dissipation
Data Source
AI summary
A light source assembly includes a plurality of light source modules detachably connected to one another. Each light source module includes a frame part, an electrical connection part, and at least one light emitting device. The frame part includes a female coupling disposed in one side surface thereof and a male coupling disposed on another side surface thereof and configured to be engaged with a female coupling of another light source module of the plurality. The electrical connection part is disposed on an upper surface of the frame part and extends onto the one side surface having the female coupling disposed therein and onto the other side surface having the female coupling disposed thereon. The at least one light emitting device is mounted on the electrical connection part and disposed on the upper surface of the frame part.