Vehicle Lamp Assembly With Thermal-Conductive Interfaces
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Solution Overview
Problem
Conventional vehicle lamps suffer from poor cooling effects due to air gaps in the connection areas between components, leading to inefficient heat transfer and potential damage to light-emitting elements from overheating.
Innovation Solution
A vehicle lamp design with a housing and carrier seat made of high thermal conductivity materials, featuring an assembling opening for easy assembly and a single air gap heat transfer path, along with continuous glue application for integral bonding of components, enhancing cooling efficiency and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional assembly methods with multiple fasteners are used, then assembly stability is improved, but assembly complexity and time increase
Solution Approach 1:
The patent merges the fastening function and positioning function into a single integrated structure. The carrier seat includes a positioning protrusion that fits into a positioning groove on the circuit board, while the same protrusion also serves as the fastening element to secure the circuit board to the housing. This integration eliminates the need for separate fasteners and positioning features, reducing assembly complexity while maintaining stability.
Solution Approach 2:
The carrier seat is designed as a multi-functional component that simultaneously provides: (1) mechanical support for the circuit board, (2) positioning through the positioning protrusion, (3) fastening through the same protrusion, and (4) thermal conduction path. This multi-functionality reduces the number of components needed and simplifies the overall assembly structure.
2Ease of operation
If air gaps are present in connection areas, then assembly ease is improved, but heat transfer efficiency deteriorates
Solution Approach 1:
The patent introduces a thermal conductive material as an intermediary substance to fill the air gap between the circuit board and the carrier seat. This thermal paste or pad serves as a mediator that conducts heat from the light emitting element through the circuit board to the carrier seat, eliminating the thermal insulation effect of air gaps while maintaining assembly ease.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the interface material by replacing air (low thermal conductivity) with thermal conductive paste (high thermal conductivity). This parameter change transforms the thermal performance of the connection interface from poor heat transfer to effective heat transfer, directly addressing the energy loss issue.
3Temperature
If cooling area is increased, then cooling effect is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling function with the existing structural components. The carrier seat, which already serves as a positioning and fastening element, is also designed as a heat dissipation component with increased surface area. The housing structure is modified to include cooling fins or increased thermal mass, integrating cooling functionality into existing components rather than adding separate cooling systems.
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 design achieves rapid and stable assembly with improved heat transfer efficiency, reducing overheating risks and increasing the cooling area, thereby enhancing the lamp's cooling effect.
Implementation Method 1
A vehicle lamp design with a housing and carrier seat made of high thermal conductivity materials, featuring an assembling opening for easy assembly and a single air gap heat transfer path
Data Source
AI summary
A vehicle lamp comprises a housing including a rear wall and an annular wall located in front of and connected to the rear wall. A chamber between the annular wall and the rear wall includes a front end having an opening. A carrier seat protrudes from an inner surface of the annular wall into the chamber and includes a mounting face facing the chamber. The annular wall includes an assembling opening facing the mounting face. A circuit board disposed on the mounting face includes at least one light emitting element and at least one first mounting hole. An optical element is disposed in the chamber to guide light rays emitted by the at least one light emitting element. A front cover is coupled with the housing and substantially seals the opening. A vertical projection of the at least one first mounting hole is substantially located in the assembling opening.