Rotating LED Modules with Standardized PCBs for Vehicle Lighting
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Solution Overview
Problem
The high cost and complexity of producing rotating LED lighting modules for vehicles stem from the need for non-standardized, curved printed circuit boards, leading to increased assembly costs and potential errors due to the requirement for each module to follow the vehicle's profile.
Innovation Solution
A compact and cost-effective lighting device design featuring identical rotating lighting modules with a cup-shaped housing, integrally connected reflectors and optical lenses, and standardized printed circuit boards with LEDs arranged in a specific configuration to achieve multiple light functions, allowing for easier assembly and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If rotating LED lighting modules are designed to follow the curved and tapered outer profile of the vehicle body, then the lighting device integrates well with the vehicle aesthetics, but the production cost increases due to non-standardized components and assembly complexity
Solution Approach 1:
The lighting device is divided into multiple identical rotating lighting modules, each capable of independent rotation. This segmentation allows each module to be manufactured as a standardized unit, reducing production costs while the collective arrangement follows the curved vehicle profile.
Solution Approach 2:
Each rotating lighting module is designed as a universal, multi-functional unit that can perform multiple lighting functions (position light, direction light, welcome light, DRL, forward low beam, fog beam). This universality eliminates the need for different customized modules, standardizing production while maintaining aesthetic integration.
2Shape
If each rotating lighting module uses a customized printed circuit board to match the curved profile, then the module fits the vehicle body contour, but the assembly costs and potential assembly errors increase
Solution Approach 1:
The curved housing profile is achieved through the spatial arrangement and rotation capability of identical modular units rather than through customized circuit boards. Each module maintains a simple, standardized internal structure with standard PCBs, reducing assembly complexity.
Solution Approach 2:
The lighting modules are designed to rotate dynamically to achieve different lighting functions and to conform to the curved housing profile during operation. This dynamic adaptation replaces the need for static, customized circuit board shapes, simplifying manufacturing and assembly.
3Illumination intensity
If multiple different rotating modules are combined to achieve required photometric performance, then the lighting functions are optimized, but the manufacturing cost and assembly time increase
Solution Approach 1:
Each rotating lighting module is designed as a universal unit capable of performing multiple lighting functions through rotation and LED configuration. This allows achieving optimized photometric performance using identical modules, dramatically increasing assembly speed and productivity compared to assembling different customized modules.
Solution Approach 2:
Multiple lighting functions (position light, direction light, welcome light, DRL, forward low beam, fog beam) are merged into a single rotating module design. This consolidation allows the same standardized module to be used throughout, simplifying assembly while maintaining comprehensive lighting 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
The solution enables a reliable, cost-effective, and efficient production of vehicle lighting devices with standardized components, reducing assembly errors and costs while maintaining combined photometric performance.
Implementation Method 1
a lighting module (5) comprising a light source and at least one reflector (6)
Implementation Method 2
at least one reflector (6) and wherein the reflector is motorized
Data Source
Figure 1
Figure 2~3
AI summary
Lighting device (1) generating given light ray distributions along an optical axis and including a cup-shaped housing (2) and a plurality of rotating lighting modules (5) arranged within the cup-shaped housing (2) and each including an optical unit (9) borne by a support (8) and arranged to rotate around a pivoting axis (A) and a printed circuit board (10) bearing a plurality of LEDs (12,13,14) and having a rectangular shape; wherein a first LED (12) is arranged at the pivoting axis (A) and at a longitudinal center line of the printed circuit board, and a pair of second LEDs (13) are arranged at forward corners (16) on the printed circuit board at positions tangent to a circumference (C) having center at the pivoting axis (A).