Vehicle Lighting Module Thermal Management via PCB Carrier
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Solution Overview
Problem
Existing motor vehicle lighting devices with semiconductor light sources face challenges in production and assembly complexity, increased space requirements, and the need for flexible and movable screened connections due to spatial separation of light sources and control modules, leading to increased costs and difficulties in movement and maintenance.
Innovation Solution
A light module design where semiconductor light sources are mounted on a carrier element with a printed-circuit board, and a control module is integrated on a separate printed-circuit board, connected via a thermally conductive carrier module, eliminating the need for separate cables and allowing for a compact, easily movable unit with improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control module is spatially separated from the semiconductor light sources and connected via cable, then electromagnetic disturbances are isolated, but the device complexity increases due to screened cables and plug connections
Solution Approach 1:
The patent merges the control module and semiconductor light sources into a single integrated circuit board assembly. The control module and LED carriers are mounted on the same printed circuit board with electrical connections made through circuit traces rather than separate cables, eliminating the need for screened cable assemblies while maintaining electromagnetic compatibility through controlled impedance design.
Solution Approach 2:
The printed circuit board serves as an intermediary structure that provides both mechanical support and electrical connection between the control module and semiconductor light sources. The circuit board's controlled impedance traces act as screened conductors, providing electromagnetic isolation while maintaining signal integrity without requiring additional cable shielding.
2Reliability
If the control module is spatially separated from the light sources, then functional independence is achieved, but the ease of operation deteriorates due to restricted movement of the light module
Solution Approach 1:
The control module and light sources are merged into a single movable assembly mounted on a common printed circuit board. This integration allows the entire lighting module to move together as one unit, providing full movement flexibility while maintaining the functional independence of the control module through its separate circuit board mounting and independent control circuitry.
3Adaptability or versatility
If the control module is spatially separated from the light sources, then modular control is enabled, but the ease of manufacture worsens due to increased assembly effort
Solution Approach 1:
The lighting device is segmented into functional modules (control module and LED carriers) that are each mounted on separate areas of the same printed circuit board. This segmentation allows for independent manufacturing and testing of each module while simplifying assembly, as the modules can be pre-assembled and pre-tested before being mounted onto the main circuit board in a single final assembly step.
4Temperature
If semiconductor light sources are mounted on a high thermal-conductivity carrier, then heat dissipation is improved, but the device complexity increases due to additional thermal management components
Solution Approach 1:
The printed circuit board serves multiple functions simultaneously: it provides electrical connections between components, mechanical support for mounting the control module and LED carriers, and thermal management through its inherent thermal conductivity. This multi-functionality eliminates the need for separate thermal management components while maintaining effective heat dissipation from the semiconductor light sources.
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 design simplifies production and assembly, reduces costs, eliminates the need for cables and plug connections, enhances heat dissipation, and allows for the semiconductor light sources and control module to be exchanged as a single unit, improving the overall efficiency and maintainability of the lighting device.
Implementation Method 1
a substantially highly thermally conductive carrier module (10) is arranged between the light source and control module
Data Source
AI summary
A light module for a vehicle lighting device comprises a semiconductor light source mounted on a carrier element designed. on/including a first printed-circuit board. A control module is electrically connected to and structurally spaced from the light source and designed on/includes a second printed-circuit board and includes an electric circuit constructed upon the second board and a connection element adapted w be connected to a higher-level controller and/or vehicle power supply. The control module is an electronic component of the light source such that a cable does not connect the control module and light source to each other. A highly thermally conductive carrier module is arranged between the light source and control module and directly attached to the carrier element, second printed-circuit board, and electric circuit. An electrical connection is located on the carrier module between the fight source or carrier element and electric circuit or second printed-circuit board.