Top-Mount LED Light Source Balancing With Adjustable Resistor
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Solution Overview
Problem
The production of light-emitting diodes for motor vehicle lighting is plagued by fluctuations in optical and electrical properties, leading to inconsistent luminous flux and difficulty in adhering to strict light distribution regulations, especially when using top mount LEDs, which complicates the selection and storage of balancing resistors.
Innovation Solution
A method where a top mount light-emitting diode is attached to a heat sink, and a resistance element is directly arranged and electrically contacted on a circuit carrier, with its resistance value adjusted based on the diode's properties, allowing for uninterrupted production and cost-effective manufacturing without the need for multiple resistor types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple types of balancing resistors are prepared and stored for different luminous flux classes, then the correct resistor can be selected for each LED, but the inventory complexity and storage requirements increase significantly
Solution Approach 1:
The patent applies parameter changes by using a single balancing resistor type with adjustable resistance value. Instead of preparing multiple resistor types with fixed different resistance values, the system uses one resistor type whose resistance can be adjusted to match the LED's luminous flux class, thereby simplifying inventory while maintaining precise matching capability
Solution Approach 2:
The patent implements universality by designing a balancing resistor that can serve multiple functions across different LED types. A single resistor design with adjustable resistance replaces multiple specialized resistor types, allowing the same component to be used for all LED luminous flux classes through resistance adjustment rather than requiring different component types
2Productivity
If circuit carriers with different adjusting resistors are produced and stored in advance, then quick selection is possible, but the production complexity and stock requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-adjusting the resistance value of the balancing resistor during the LED mounting process itself. The resistance is adjusted based on the specific LED's properties before final assembly, eliminating the need to pre-produce and store multiple types of circuit carriers with different resistors
Solution Approach 2:
The patent uses parameter changes by adjusting the resistance value of a single resistor type during the manufacturing process rather than producing multiple fixed-resistor types. This allows the resistance parameter to be dynamically changed to match each LED's requirements, simplifying production while maintaining speed
3Device complexity
If the resistance value is adjusted after LED mounting, then a single resistor type can be used, but the adjustment process adds time to production
Solution Approach 1:
The patent applies preliminary action by performing the resistance adjustment during the LED mounting process itself, rather than as a separate subsequent step. This timing integration ensures the resistor is ready before final assembly without adding overall production time
Solution Approach 2:
The patent implements continuity of useful action by integrating the resistance adjustment into the continuous LED mounting flow. The adjustment happens in-situ during assembly operations, maintaining production continuity rather than interrupting the process for separate adjustment steps
4Adaptability or versatility
If SMD LEDs are connected to circuit carriers in downstream processes, then flexibility is improved, but the coordination of resistor selection and LED mounting becomes more difficult
Solution Approach 1:
The patent applies preliminary action by preparing the balancing resistor with the correct resistance value before the LED is mounted on the circuit carrier. This preliminary preparation ensures that when the LED arrives for mounting, the matching resistor is already ready, eliminating coordination delays in downstream processes
Solution Approach 2:
The patent uses an intermediary approach by having the balancing resistor prepared in advance as a separate component before final assembly. This allows the resistor selection and LED mounting to be coordinated through a standardized interface, maintaining flexibility while simplifying the coordination process
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 approach enables the production of a balanced light source arrangement for top mount LEDs in a simple and cost-effective manner, reducing waste and ensuring consistent brightness across motor vehicle lighting devices by adjusting the resistance value post-assembly, thus meeting regulatory standards.
Implementation Method 1
at least one top-mount light-emitting diode is attached to a heat sink
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method (51) for manufacturing a light source arrangement (13) for a motor vehicle illumination device (101) having at least one light-emitting diode (15) for generating light and a resistance element (17) for specifying properties of the light-emitting diode (15) to a control device (31; 107) in order to control the light source arrangement (13) in an open-loop and/or closed-loop manner. The invention relates to a method having the following steps: - providing (55) a heat sink (24), - providing (57) at least one top-mounted light-emitting diode (15), - fastening (57) the at least one top-mounted light-emitting diode (15) on the heat sink (24), - providing (59) a circuit carrier (21), - arranging (59) the resistance element (17) on the circuit carrier (21), - establishing (61) an electrical connection (28) between the circuit carrier (21) and the at least one top-mounted light-emitting diode (15), - detecting (63) the properties of the light-emitting diode (15), and - adjusting (65) a resistance value (R) of the resistance element (17) in accordance with the detected properties of the light-emitting diode (15).