Vehicle Lamp Wiring Harness Layout for Low-Torque Module Rotation
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Solution Overview
Problem
Conventional lighting modules for vehicle lamps rely on costly flexboards for electrical connections, which require additional wires and cables, leading to rigidity in the wiring harness and increased torque requirements for movement, compromising the freedom of movement and durability of the lighting module.
Innovation Solution
A cost-effective electrical connection assembly for vehicle lamp lighting modules is introduced, utilizing a main connector connected to a power supply via a primary wire harness, with two sub-wire harness portions branching out to secondary connectors, minimizing the number of wire harness routings and optimizing power supply to various electric loads without using flexboards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flexboard is used for electrical connections in the lighting module, then electrical power can be provided to different loads, but the wiring harness becomes rigid and torque requirements for movement increase
Solution Approach 1:
The wire harness is segmented into multiple independent routing paths (first routing and second routing) that branch out from the housing toward the light generator. This segmentation allows the wiring harness to flex and move independently in different directions, reducing rigidity and torque requirements while maintaining electrical connectivity.
2Adaptability or versatility
If additional wires or cables are added to power electric loads like the fan, then all electric loads can be powered, but the wiring harness becomes more rigid and requires more torque for movement
Solution Approach 1:
The wire harness is designed with dynamic routing that allows different paths for different electrical connections. The first and second routings can adapt their configuration based on the specific electric loads being powered, enabling versatile power distribution while maintaining flexibility through multiple possible wire paths rather than a single rigid structure.
3Device complexity
If a single routing for the wiring harness is used, then assembly is simplified, but the lighting module requires more torque for movement and has reduced freedom of movement
Solution Approach 1:
The wire harness is divided into multiple routing paths (first routing and second routing) that branch out from the housing. This segmentation creates a more complex but flexible wiring structure that can accommodate movement better than a single rigid routing, reducing the torque required for lighting module rotation.
4Reliability
If conventional wiring methods are used, then electrical connections can be established, but the cost increases due to flexboard requirements
Solution Approach 1:
The patent replaces expensive flexboard components with conventional wire harnesses that can be easily manufactured and replaced. The wire-based electrical connections provide sufficient reliability for the application while significantly reducing manufacturing costs compared to flexboard-based solutions.
Data Source
Figure 1A~1B
Figure 1C~2A
Figure 2B~3
AI summary
The present invention relate to a lighting module (100) for a vehicle lamp of an automotive vehicle, the lighting module (100) comprising an electrical connection assembly (125) having a main connector (130) electrically connected to a power supply (135) of the vehicle lamp by a primary wire harness (140); a plurality of secondary connectors (150a, 150b, 150c, 150d) configured to provide the power supply (135) to a plurality of electric loads of the vehicle lamp. Further, the lighting module (100) comprises two sub-wire harness portions (155a, 155b) branching out from the main connector (130) and routed along longitudinal sides of the lighting module (100) to electrically connect the main connector (130) and the plurality of secondary connectors (150a, 150b, 150c, 150d).