Vehicle Light Module Reflector Projections for Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current motor vehicle lighting devices face challenges in achieving precise positioning of semiconductor light sources due to fluctuations in paint layer thickness and uniformity during the painting process, leading to inaccuracies in the adhesive connection between the circuit carrier and reflector.
Innovation Solution
The reflector's mounting area features projections coated with lacquer, allowing the adhesive to be applied between or next to these projections, which reduces the impact of paint layer thickness on positioning accuracy, utilizing surface tension effects to maintain a thin lacquer layer on projections, thus ensuring consistent placement of the circuit carrier independent of adjacent surface lacquer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flood painting is used to coat the reflector, then painting efficiency is improved, but the uniformity of paint layer thickness on the mounting area deteriorates
Solution Approach 1:
The mounting area is segmented into multiple regions by projecting upward from the surface, creating distinct zones where adhesive can be applied between or next to the projections. This segmentation allows the adhesive to accommodate variations in paint layer thickness while maintaining consistent bonding, thereby resolving the contradiction between efficient flood painting and precise positioning requirements
2Reliability
If the adhesive layer thickness is increased to ensure proper bonding, then bonding reliability is improved, but the positioning accuracy of the semiconductor light source deteriorates
Solution Approach 1:
The projections on the mounting area serve as intermediary elements between the reflector and the circuit carrier. These projections create a standardized interface that defines the position of the semiconductor light source, allowing the adhesive to bond reliably without compromising positioning accuracy. The projections mediate between the adhesive connection requirement and the positioning precision requirement
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 results in reduced positional fluctuations of the circuit carrier, enhancing the accuracy and reproducibility of the semiconductor light source's placement within the reflector, automatically improving assembly precision without additional effort.
Implementation Method 1
It has been shown that, due to surface tension effects, there is an edge alignment of paint on the projections protruding from the remaining surface of the mounting area. The result of this edge alignment is that only a very thin layer of lacquer can hold on the projections, the layer thickness of which is largely independent of the layer thickness of the lacquer layer on the areas of the mounting area adjacent to the projections.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
What is presented is a light module for a motor vehicle illumination device, comprising at least one semiconductor light source which is arranged on a circuit carrier, and comprising a reflector which is coated with a varnish and which has a mounting region coated with the varnish, said mounting region having a broad side and a narrow side and the circuit carrier being secured thereto by an adhesive bond. The light module is distinguished by the fact that the mounting region has a surface with projections which are coated with the varnish and on which the circuit carrier lies at a distance from the remaining surface of the mounting region and wherein the adhesive bond is produced by an adhesive applied next to the projections or between the projections over at least part of the remaining surface of the mounting region.