Vehicle Optical Module With Direct Lens-to-Heatsink Mounting

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Solution Overview

Problem

Existing optical modules for vehicle lighting and signaling devices incur additional costs and require precise dimensional management due to separate plastic supports between the optical component and the cooling device, leading to manufacturing challenges and increased tolerance issues.

Innovation Solution

The optical module integrates the focusing device directly to the cooling device, eliminating intermediate components and using fastening means that absorb dimensional tolerances and thermal expansions, ensuring precise alignment and reduced costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If an intermediate plastic support is used between the optical component and the cooling device assembly, then the components can be mounted separately with manufacturing tolerances, but the overall cost increases and assembly precision decreases

Engineering Contradiction:

Improvemanufacturing tolerance managementVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the intermediate plastic support with the optical component itself, creating an integrated assembly where the support structure is formed as part of the optical component manufacturing process. This eliminates the need for a separate intermediate support component while maintaining the necessary spacing and alignment functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The optical component is designed to serve multiple functions: it provides optical functionality, structural support, spacing maintenance, and mounting integration. By making the optical component multi-functional, the patent eliminates the dedicated intermediate support component while preserving all necessary functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If an intermediate plastic support is used between the assembly and the optical component, then the components can be assembled separately, but the manufacturing cost and tolerance management complexity increase

Engineering Contradiction:

Improveassembly processVSAvoiddimensional chain precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The support structure is integrated into the optical component, reducing the dimensional chain from multiple separate components to a single integrated unit. This eliminates cumulative tolerance issues while simplifying the assembly process.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If separate components are used with an intermediate support, then manufacturing flexibility is maintained, but overall production cost increases

Engineering Contradiction:

Improvecomponent configuration flexibilityVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into the optical component itself, reducing the total part count while maintaining design flexibility through integrated features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The optical component is designed as a multi-functional element that provides optical performance, structural support, spacing, and mounting capabilities, eliminating the need for dedicated intermediate support parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 integration reduces costs and improves assembly reliability by eliminating intermediate parts, enhancing precision and reliability of the optical module.

Implementation Method 1

a cooling device (3) designed to capture at least the heat generated by the light source (2) and dissipate it into the air surrounding the optical module (1)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

dissipate it into the air surrounding the optical module (1)

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

The function of the focusing device is to concentrate the light rays emitted by the source and direct them towards a specific area of the road to be illuminated

Methodology Applied

Scientific EffectOptical focusing: Focusing

Implementation Method 4

at least one collector, or collector element comprising a plurality of collectors, capable of reflecting the light beam emitted by the light source at least towards the focusing device

Methodology Applied

Scientific EffectOptical reflection: Reflection

Data Source

PatentEP2756222B1Optical module with common part reference for motor vehicle lighting and/or signalling

Publication Date: 2026.01.28 VALEO VISION SA

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AI summary

The invention relates to an optical module (1) for a vehicle lighting and/or signalling device, comprising at least one light source (2, 7) to (9) able to generate a light beam, a cooling device (3) able to dissipate heat and a device (4) for focusing the light beam, characterized in that the focusing device (4) is carried directly by the cooling device (3).