Segmented Light Source Module Heat Sink for Vehicle Headlamps
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Solution Overview
Problem
The existing methods for manufacturing light source modules for vehicle headlamps require a new mold for each vehicle model, leading to high manufacturing and investment costs due to the need for customized heat sink structures.
Innovation Solution
A standardized light source module structure featuring a frame with multiple mounting surfaces and heat dissipaters, allowing for flexible attachment of heat dissipaters to accommodate different vehicle models, reducing the need for multiple molds and enabling mass production of heat sink structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a customized heat sink structure is designed for each vehicle model, then the heat dissipation efficiency is improved, but the manufacturing cost and investment cost increase due to the need for multiple molds
Solution Approach 1:
The heat sink structure is divided into a standardized frame and multiple interchangeable heat dissipaters. The frame provides a common mounting platform while different heat dissipaters can be attached based on specific vehicle model requirements, allowing customized heat dissipation solutions without requiring customized molds for each model.
Solution Approach 2:
The standardized frame structure with multiple mounting surfaces can accommodate different types of heat dissipaters for different vehicle models. This universal base structure reduces the need for multiple specialized molds while maintaining the ability to provide model-specific heat dissipation performance.
2Ease of manufacture
If a standardized heat sink structure is used across different vehicle models, then the manufacturing cost is reduced, but the heat dissipation efficiency may be compromised
Solution Approach 1:
By segmenting the heat sink into a universal frame and model-specific heat dissipaters, the standardized frame maintains manufacturing efficiency while the interchangeable heat dissipaters ensure optimized heat dissipation for each vehicle model's specific requirements.
Solution Approach 2:
The system allows dynamic configuration where different heat dissipaters can be attached to the standardized frame depending on the vehicle model, enabling the heat dissipation system to adapt to different thermal requirements while using a common manufacturing platform.
3Adaptability or versatility
If multiple customized molds are manufactured for different vehicle models, then the design requirements for each model are met, but the investment cost and management complexity increase
Solution Approach 1:
The mold investment is segmented into one standardized frame mold and multiple smaller heat dissipater molds. This reduces the overall complexity compared to creating entirely customized molds for each vehicle model, while still allowing design adaptability through the interchangeable heat dissipaters.
Solution Approach 2:
The standardized frame mold serves multiple vehicle models universally, reducing the total number of molds required. Only the heat dissipater portions need model-specific customization, significantly simplifying mold management compared to fully customized approaches.
4Ease of operation
If a standardized frame structure with multiple mounting surfaces is used, then the ease of assembly and maintenance is improved, but the structural complexity of the frame increases
Solution Approach 1:
The frame's multiple mounting surfaces are strategically positioned to accommodate different heat dissipater configurations. This segmentation of mounting locations provides assembly flexibility and ease of maintenance while keeping the overall frame structure relatively simple and standardized.
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 solution allows for the use of a common heat sink structure across various vehicle models, reducing manufacturing costs and investment by eliminating the need for separate molds for each model, while maintaining efficient heat dissipation and accommodating diverse design structures.
Implementation Method 1
a plurality of heat dissipaters respectively disposed on the plurality of mounting surfaces and extending to cover one of the side surfaces of the frame
Data Source
AI summary
A light source module includes a frame having a plurality of mounting surfaces at different levels and side surfaces respectively connected to the plurality of mounting surfaces; a plurality of heat dissipaters respectively disposed on the plurality of mounting surfaces and extending to cover a side surface of the frame; and a light source including a plurality of light emitting devices respectively disposed on the plurality of heat dissipaters and respectively positioned above the plurality of mounting surfaces.