Twistable Light Source Support for Curved Automotive Surfaces
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Solution Overview
Problem
Existing Printed Circuit Boards (PCBs) are not flexible and cannot be accommodated on curved surfaces, requiring multiple PCBs for curved applications, which increases complexity and cost due to the need for additional harnesses and complex assembly processes.
Innovation Solution
A twistable and rotatable light source support is created by structurally joining two non-flexible parts with a flexible arm, allowing the light source support to be positioned on curved elements without additional harnesses, enabling a single design for multiple packaging platforms and manufacturing in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid PCB is used for mounting light sources, then structural stability and electrical connectivity are ensured, but the PCB cannot be accommodated on curved surfaces
Solution Approach 1:
The PCB is divided into multiple rigid segments (first PCB segment, second PCB segment) that are connected by a flexible hinge, allowing each segment to maintain structural stability while the assembly as a whole can adapt to curved surfaces through the hinge's flexibility
Solution Approach 2:
A flexible hinge connecting the rigid PCB segments, enabling the PCB assembly to bend and conform to curved lamp module surfaces while maintaining electrical connectivity between segments
2Area of stationary object
If multiple rigid PCBs are used to cover curved surfaces, then complete surface coverage is achieved, but the device complexity increases due to additional harnesses and assembly processes
Solution Approach 1:
The PCB is divided into multiple rigid PCB segments that can be arranged to cover curved surfaces, with each segment maintaining structural stability while the flexible hinge enables adaptation to the curved geometry
Solution Approach 2:
Multiple rigid PCB segments are merged into a single integrated assembly through flexible hinges, eliminating the need for separate harnesses and complex assembly processes while maintaining complete surface coverage
3Adaptability or versatility
If a rigid PCB is deformed to fit curved surfaces, then adaptability to curved surfaces is improved, but stress is created in the welding area compromising system reliability
Solution Approach 1:
The PCB is segmented into rigid sections connected by flexible hinges, allowing the rigid segments to maintain their structural integrity and welding reliability while the flexible hinge absorbs the deformation needed to fit curved surfaces
Solution Approach 2:
A flexible hinge connects rigid PCB segments, providing the necessary adaptability to curved surfaces without requiring deformation of the rigid PCB segments themselves, thus preserving welding area reliability
Data Source
AI summary
The present invention relates to a light source support of an automotive vehicle. The light source support comprises: a first non-flexible part adapted to be mounted with a plurality of first electronic components; and a second non-flexible part adapted to be mounted with a plurality of second electronic components. The light source support further comprises a flexible arm adapted to join the first non-flexible part and the second non-flexible part to form the light source support, which is twistable and rotatable. The first non-flexible part and the second non-flexible part are joined in a non-axial manner by the flexible arm such that a longitudinal axis of the first non-flexible part is not parallel to a longitudinal axis of the second non-flexible part when the first non-flexible part is joined with the second non-flexible part.