Monolithic Optical Module Heat Sink Lens Integration
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Solution Overview
Problem
Existing optical modules for motor vehicle lighting and signaling devices have complex structures and assembly processes, requiring precise tolerances and complex dimension chains, making them difficult to assemble and manufacture.
Innovation Solution
A simplified optical module design featuring a support that directly connects an optical lens and a heat exchanger, with optional integration of a fan, reflectors, and air channeling means, allowing for easier assembly and orientation, and incorporating a base with articulation means for rotational adjustment within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the light source is mounted on a heat sink with airflow directed over it for heat dissipation, then the lighting device achieves high performance, but the structure becomes complex and assembly becomes complicated
Solution Approach 1:
The patent combines the heat sink and optical lens into a single integrated component. The heat sink serves dual functions: dissipating heat from the LED and supporting the optical lens that focuses light. This eliminates the need for separate heat sink and lens assemblies, reducing structural complexity while maintaining effective heat dissipation through the heat sink's fin structure and airflow channels.
2Reliability
If multiple parts are assembled together to create the lighting device, then the heat dissipation function is achieved, but numerous tolerances must be established and dimensional chains become complex
Solution Approach 1:
By integrating the heat sink and optical lens into one monolithic component, the patent eliminates multiple assembly interfaces and dimensional chains. The single-piece construction removes the need to establish tolerances between separate heat sink and lens assemblies, significantly reducing manufacturing precision requirements while maintaining the heat dissipation function through internally integrated cooling channels and fin structures.
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
The solution results in a more straightforward assembly process, reduced complexity in dimension chains, and improved optical performance, while maintaining effective heat dissipation and adaptability to vehicle maneuvers.
Implementation Method 1
the light source is mounted on a heat sink over which an airflow is directed, so that some of the heat produced by the light source is dissipated by the heat sink into the airflow
Implementation Method 2
an airflow is directed, so that some of the heat produced by the light source is dissipated by the heat sink into the airflow
Data Source
Figure 1
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AI summary
Optical module (1; 1') of a lighting and/or signaling device of a motor vehicle, comprising a reflector associated with a light source, in particular comprising an LED, for reflecting light from that light source, that reflector being formed on a piece, in particular monolithic, namely made in one piece, provided with a cooling opening (50) for cooling air circulation.