Flat Vehicle Lighting Device with Narrow-Face LED Mounting
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Solution Overview
Problem
Conventional lighting devices for vehicles require extensive installation space, complex assembly, and bulky housings due to the intricate positioning of LEDs on circuit boards, leading to increased weight, material usage, and costs, as well as restrictive design options.
Innovation Solution
A compact, flat lighting device design featuring a circuit board with discretionary shape, where LEDs are positioned on the narrow face and connected to conductive paths, allowing for simplified assembly and integration into small housings, using SMD-LEDs or standardized LEDs with wire-like contacts for reliable and efficient illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are positioned on circuit boards with conductive paths on both surfaces, then reliable electrical connection is achieved, but installation space increases and housing becomes bulky
Solution Approach 1:
The patent repositions LEDs from the broad face of the circuit board to the narrow face, utilizing the previously underutilized narrow surface area. This dimensional repositioning allows the LED array to be arranged along the length of the narrow face rather than spreading across the broad face, significantly reducing the required installation space while maintaining all necessary electrical connections through the circuit board's conductive paths.
2Adaptability or versatility
If circuit boards are provided in individual segments for curved housings, then housing contour compatibility is achieved, but assembly complexity and cost increase
Solution Approach 1:
The patent divides the circuit board into multiple segments or modules, each capable of being independently positioned and assembled. These segments can be arranged in different configurations to match various housing contours, including curved surfaces. The segmentation allows for flexible assembly where segments are connected through standardized interfaces, reducing overall assembly complexity compared to custom-shaped single-piece circuit boards.
Solution Approach 2:
The circuit board segments are designed with universal mounting features and standardized connection points that can accommodate different housing types and contours. This multi-functionality allows the same segment design to be used across various applications and housing configurations, reducing the need for custom-designed segments for each specific housing contour.
3Illumination intensity
If additional optical components are added for efficient illumination, then illumination efficiency improves, but positioning precision requirements increase and installation complexity increases
Solution Approach 1:
The patent integrates the optical components directly with the LED assembly on the circuit board, merging multiple functions into a single integrated unit. The reflectors, lenses, or other optical elements are positioned in fixed relationships with the LEDs through the circuit board structure itself, eliminating the need for separate positioning mechanisms and reducing precision requirements for separate component alignment.
4Illumination intensity
If conventional lighting device configurations are used, then adequate illumination is achieved, but weight and material usage increase
Solution Approach 1:
The patent extracts and eliminates unnecessary components and structural elements from conventional lighting device configurations. By repositioning LEDs to the narrow face of the circuit board, supporting structures, housing materials, and mounting components can be minimized or removed entirely, achieving adequate illumination with significantly reduced weight and material usage.
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 configuration results in a lightweight, cost-effective, and aerodynamically advantageous lighting solution with reduced installation complexity, enabling design flexibility and integration into various vehicle components without significant optical errors, while providing durable and efficient illumination.
Implementation Method 1
The circuit board has conductive tracks that serve for contacting and positioning of the LEDs
Implementation Method 2
LEDs are disposed on circuit boards
Implementation Method 3
illuminant unit with illuminants disposed at the front face of a circuit board
Data Source
AI summary
A lighting device with at least one lighting unit for vehicles, preferably motor vehicles. The lighting device comprises at least one illuminant unit with one circuit board, and with at least one illuminant attached to the circuit board, connected to the conductive paths of the circuit board through contacts. The illuminant is positioned at the front face of the circuit board in order to configure the lighting device so that it can be manufactured simply and economically in a particularly flat configuration and in any curved shape. The lighting device is advantageously used in vehicles, preferably in motor vehicles.