Modular Lighting Adapter for Thermal Decoupling
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Solution Overview
Problem
Existing LED-based automotive lighting assemblies face challenges with high production costs and limited thermal performance due to complex manufacturing techniques and solder-based technologies, which can lead to solder connection failures at elevated operating temperatures.
Innovation Solution
A modular lighting assembly with a separate base part for mounting LEDs and an adapter part that includes electrical components and connectors, providing a thermal interface, mechanical interface, and electrical connector interface, allowing for decoupling of electrical components from LEDs and enabling higher operating temperatures with reduced thermal management efforts and lower production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder-based technologies are used to mount LED chips and electrical components on a PCB or IMS, then electrical connections are established, but the thermal performance is limited and operating temperature is restricted to maximum 125°C
Solution Approach 1:
The invention divides the lighting assembly into separate modular components: a base part with LED chips and an adapter part with electrical components. This segmentation eliminates the need for soldering between these modules, allowing each to be optimized independently for thermal performance and reliability.
Solution Approach 2:
The invention extracts the electrical components from the traditional soldered PCB/IMS structure and places them in a separate adapter part. This extraction removes the thermal limitation imposed by solder joints, enabling the LED base part to operate at higher temperatures without compromising solder connection reliability.
2Reliability
If complex manufacturing techniques with soldering steps are used, then electrical connections are established, but production costs increase
Solution Approach 1:
The invention segments the manufacturing process into simpler, separate steps for the base part and adapter part, eliminating complex soldering operations. Each module can be manufactured using simpler techniques, reducing overall manufacturing complexity and cost while maintaining connection reliability through mechanical interfaces.
Solution Approach 2:
The invention replaces the solder-based mechanical system with a mechanical connection system using the adapter part. This substitution eliminates the need for soldering equipment and processes, simplifying manufacturing while maintaining reliable electrical connections through the adapter's contact surfaces.
3Adaptability or versatility
If electrical components are integrated on the same PCB/IMS as LED chips, then circuit functionality is achieved, but thermal management becomes challenging
Solution Approach 1:
The invention segments the thermal zones by separating heat-generating LED chips from other electrical components into different modules. The base part contains only LED chips optimized for high-temperature operation, while the adapter part houses other components that require lower operating temperatures, simplifying thermal management.
Solution Approach 2:
The invention extracts electrical components from the LED mounting substrate and places them in a separate adapter part. This extraction creates thermal decoupling, allowing the LED base part to be optimized for high-temperature operation without being constrained by the thermal requirements of other electrical components.
Data Source
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AI summary
The invention describes an adapter part (2, 9) for a modular lighting assembly (1) comprising a number of light-emitting diodes (4) mounted on a separate base part (3), which adapter part (2, 9) comprises a number of first electrical connectors (21) arranged to connect the light-emitting diodes (4) to an external power supply; at least one electrical component (5) arranged in a body of the adapter part (2, 9); and a number of second electrical connectors (22) arranged to connect external circuitry to an electrical component (5) arranged in the body of the adapter part (2, 9). The invention further describes a modular lighting assembly (1) comprising a base part (3) upon which a number of light-emitting diodes (4) is mounted; and an adapter part (2, 9) according to the invention. The invention also describes a method of assembling such a modular lighting arrangement (1), comprising the steps of connecting a first adapter part (2, 9) according to the invention to a separate base part (3); choosing a number of electrical components (5, 6) on the basis of an application requirement of the modular lighting arrangement (1); and arranging an electrical component (5, 6) in the adapter part (2, 9) such that an electrical connection is formed between a contact surface of the electrical component (5, 6) and a second electrical connector (22) of the adapter part (2, 9).