Thin Plate Metal PCB Headlight Module with Protruded Heat Dissipation

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Solution Overview

Problem

Conventional metal PCB assemblies for vehicle lamps require complex processes and are prone to damage during bending, leading to increased production costs and error rates due to the need for curved grooves and specific angled protrusions.

Innovation Solution

A headlight module featuring a thin plate type metal PCB that can be bent in various directions with protruded portions for enhanced heat dissipation, integrated chip mounting parts, and a simplified back plate structure with contact support jaws and latching mechanisms for easy assembly and reduced production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If curved grooves are formed at the bottom of the metal board to bend unit patterns, then the metal PCB assembly can achieve the desired shape, but the work process is increased and the metal board is broken upon bending

Engineering Contradiction:

Improvestepped shape of metal PCB assemblyVSAvoidwork process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The metal PCB is divided into a body portion and multiple unit patterns that are separately formed and then integrated. Each unit pattern can be independently shaped and mounted, eliminating the need for complex curved grooves in the base metal board. This segmentation allows simpler forming processes for each component while achieving the overall stepped shape through assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of bending the unit patterns by forming curved grooves in the metal board (traditional approach), the invention inverts the approach by providing pre-formed unit patterns with inclined surfaces that are then mounted onto the metal PCB body. The shaping operation is performed on separate components rather than through complex substrate deformation.

Inventive Principle:

Principle #13The other way round (Inversion)

2Shape

If curved grooves of specific depth are formed to bend unit patterns, then the desired angled configuration is achieved, but the metal board breaks upon bending

Engineering Contradiction:

Improveinclined unit pattern configurationVSAvoidmetal board integrity

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The unit patterns are separated from the base metal board and formed as independent components. Each unit pattern is pre-formed with the required inclined configuration, eliminating stress concentration and cracking issues that occur when bending the continuous metal board. The base metal PCB remains intact while the unit patterns provide the necessary angular geometry.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The unit patterns are pre-formed with their final inclined shapes before being mounted onto the metal PCB body. This preliminary shaping avoids the need to bend the metal board during assembly, preventing metal board breakage while achieving the desired angled configuration of LED mounting surfaces.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If unit patterns are fully separated from the metal PCB, then manufacturing flexibility is improved, but the unit pattern cannot maintain a specific angle without additional support structures

Engineering Contradiction:

Improveunit pattern fabrication flexibilityVSAvoidsupport structure requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The unit patterns are integrated with the metal PCB body through protrusions that extend from the unit patterns and engage with corresponding recesses in the metal PCB. This merging provides both the flexibility of separate fabrication and the stability of angular positioning, eliminating the need for additional support structures while maintaining precise inclined configurations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection between unit patterns and metal PCB is achieved through protrusions extending in the vertical dimension rather than through complex lateral support structures. This dimensional approach simplifies the overall structure while maintaining the inclined angular configuration of the unit patterns.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 allows for flexible shape application, maximized heat dissipation, reduced production costs and worker requirements, and minimized assembly errors by simplifying the assembly process and structure, while maintaining effective heat management and mounting accuracy.

Implementation Method 1

a metal PCB formed of a thin plate which is a thermal conductor

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10551026B2Headlight module having thin plate type metal PCB

Publication Date: 2020.02.04 ECOCAB

AI summary

Provided is a headlight module having a thin plate type metal PCB, wherein the headlight module has the assembly structure of a metal PCB formed of a thin plate which is a thermal conductor and capable of being bent in various directions and including at least one protruded portion increasing a surface area on both sides, and a back plate coupled to the metal PCB through the protruded portion.