Segmented Heat Sink for Automotive Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing heat sinks used in automotive exterior or interior lighting are complex and costly to manufacture, and they often obstruct the easy mounting of LEDs due to their L-shape design.
Innovation Solution
A heat sink design that allows for easy mounting of LEDs by forming two identical heat sinks with receiving portions and connection portions, which can be thermally connected to form a single assembly, thereby simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a complex die-cast freeform or combination of multiple extruded/stamped structures is used for dual function module heat sink, then the heat dissipation capability is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The heat sink is divided into two separate L-shaped heat sink units, each capable of independent manufacturing through simple processes. These segmented units are then arranged side-by-side to form a dual-function heat dissipation structure, avoiding the need for complex die-cast freeform or multiple extruded/stamped structures while maintaining effective heat dissipation capability.
2Strength
If the heat sink has an L-shape design with side walls, then the structural integrity is improved, but the LED mounting process becomes difficult due to placement head collisions
Solution Approach 1:
By segmenting the heat sink into two separate L-shaped units positioned side-by-side, the placement head can access the LED mounting area from the front without colliding with side walls. The side walls are positioned on opposite sides of the two units, creating clear access paths for automated placement heads to mount LEDs in tilted positions.
Solution Approach 2:
The design transitions from a single integrated L-shaped structure to two separate L-shaped structures arranged in a side-by-side configuration. This dimensional reorganization creates spatial separation between the side walls and the LED mounting zone, allowing placement heads to operate in the cleared space without collisions while maintaining structural integrity through the connection portion.
3Adaptability or versatility
If multiple units are placed next to each other or stacked, then multiple lighting functions are enabled, but the heat sink construction becomes complex requiring multiple components
Solution Approach 1:
The heat sink is segmented into two identical L-shaped units, each designed to support a lighting module for different lighting functions (e.g., high beam and low beam). This segmentation enables multiple lighting functions while keeping each unit structurally simple and manufacturable through straightforward processes, avoiding the need for complex integrated designs or multiple different components.
Solution Approach 2:
Instead of designing a complex single heat sink structure to accommodate multiple lighting functions, the invention uses two identical copies of a simple L-shaped heat sink unit. Each unit is a straightforward structure that can be manufactured easily, and when placed side-by-side, they collectively provide the required multiple lighting functions without increasing individual component complexity.
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 proposed heat sink design enhances manufacturing efficiency and reduces costs while ensuring effective heat dissipation and easy LED mounting, making it suitable for automotive lighting applications.
Implementation Method 1
A light emitting device (for example a LED) is attached to the heat sink so that the heat from the operating lighting module can safely dissipate
Implementation Method 2
the at least one connection portion is in thermal contact to such at least one corresponding connection portion of the other heat sink when the heat sink is connected to the other heat sink
Data Source
Figure 1~2
Figure 3
Figure 4a~4b
AI summary
The invention refers to a heat sink (2a) for being mounted to another same heat sink (2b), the heat sink (2a) comprising: at least one receiving portion (12a) for at least one lighting module (6), wherein the at least one lighting module (6) is to be thermally connected to the heat sink (2a), at least one connection portion (14a) for connecting the heat sink (2a) to such at least one connection portion (14b) of the other heat sink (2b), wherein the at least one connection portion (14a) is in thermal contact to such at least one corresponding connection portion (14b) of the other heat sink (2b) when the heat sink (2a) is connected to the other heat sink (2b). The invention further relates to a lighting device (4) and a method employed in the production of the lighting device (4).