Insect repeller with circuit board supporting structure

Abstract

A light emitting insect killer includes a heater assembly, an electrical power source, an insect killer power switch, a power button assembly including a condition indicator lens, an insect killer power button, and at least one light tube optically connected to the condition indicator lens and configured to project light from a light source to the condition indicator lens. The insect repeller power switch is in electrical communication between the electrical power source and the heater assembly.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 428,937, filed on November 30, 2022, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention generally relates to insect repellers. In particular, the present invention relates to an improved printed circuit board (PCB) assembly and a method for assembling a PCB assembly. Background Art

[0004] Outdoor spaces provide attractive venues for people to gather, dine, and relax. However, these spaces also attract insects and other pests, which can hinder effective area utilization, especially in commercial settings, creating an undesirable environment that reduces profitability and can have an adverse impact on the reputation of the facility. Individual insect repellers are known and form defined pest - protected areas. While these devices work well, they are operated independently and may not provide efficient utilization of volatile substances, which increases costs. Other devices are known to be linked together to power heating elements but are unable to adjust the operation of the devices in response to environmental conditions or system performance levels.

[0005] The ability to conveniently and effectively control the outdoor environment for insect repelling or creating an atmosphere is hindered by the insect repeller's ability to convey and coordinate operating conditions, adjust output parameters based on local conditions, and adapt different materials and outputs to provide different environmental effects such as odor regulation, lighting control, and audio output. Additionally, outdoor environments present adverse conditions such as rain, wind, and temperature variations, which reduce the ability to efficiently utilize emission materials. Accordingly, there is a desire to provide an outdoor environment control system that provides the ability to reduce pest presence, provide a pleasant sensory atmosphere, be illuminated, be easier to assemble, and resist negative environmental factors that affect the operation of the device. Summary of the Invention

[0006] The present invention generally relates to insect repellers. In particular, the present invention relates to an improved printed circuit board (PCB) assembly and a method for assembling a PCB assembly.

[0007] In one embodiment, a lighted insect repeller includes a heater assembly, a power source, an insect repeller power switch, a power button assembly including a status indicator lens, an insect repeller power button, and at least one light tube optically connected to the status indicator lens and configured to project light from a light source onto the status indicator lens. The insect repeller power switch is in electrical communication between the power source and the heater assembly.

[0008] In a second embodiment, a PCB assembly for a repellent device includes a PCB mounting bracket having a base and a PCB access opening formed therethrough. The PCB has a first side and a second side and includes a microcontroller, one or more functional electronic components, and a power switch having a power switch post extending outwardly therefrom, the power switch post being electrically mounted to the first side of the PCB and configured to operate the repellent device. The PCB is mounted within a recess formed in the PCB mounting bracket. A plurality of first spring pins are mounted to the first end of the PCB. An electrical connector is mounted to the base of the PCB mounting bracket, the electrical connector having a plurality of second spring pins and electrical leads extending from the electrical connector through the PCB access opening to the second side of the PCB. The light tube subassembly includes: a light tube housing having a button opening formed centrally therein, an attachment arm extending outwardly therefrom, and a plurality of light tubes, the attachment arm extending through the PCB and into the PCB mounting bracket; a power button mounted within the button opening; a status indicator lens attached to the light tube subassembly; and a spring mounted between the power switch post and the power button.

[0009] Furthermore, a method of assembling a PCB assembly for a repellent device includes: mounting electrical components necessary to operate the repellent device to the first side of the PCB, the electrical components including at least one of a microcontroller, one or more functional electronic components, and a power button having a power switch post extending outwardly therefrom, the power switch post being electrically mounted to the first side of the PCB and configured to operate the repellent device. Placing a plurality of first spring pins onto the post and thermally fusing the post to lock the plurality of spring pins in place at the first end of the PCB. Mounting an electrical connector to the base of the PCB mounting bracket, the electrical connector having a plurality of second spring pins and electrical leads extending from the electrical connector. Mounting the PCB into a recess formed in the PCB mounting bracket and connecting the electrical leads of the spring pins from the electrical connector on the base of the bracket through the PCB access opening to the second side of the PCB. Providing a light tube subassembly and the light tube subassembly includes a light tube housing having a button opening formed centrally therein, an attachment arm extending outwardly therefrom, and a plurality of light tubes. Pushing down the button to snap it into the button opening of the light tube subassembly. Attaching a spring to the power switch post and passing the attachment arm of the light tube subassembly through the PCB and snapping it onto the PCB mounting bracket, thereby attaching the light tube subassembly to both the PCB and the PCB mounting bracket and compressing the spring. Snapping a status indicator lens onto the light tube subassembly, thereby defining the PCB assembly.

[0010] When read in conjunction with the accompanying drawings, various aspects of the present invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective view of a first embodiment of a light-emitting repellent device according to the present invention.

[0012] Figure 2 is Figure 1 a front view of the light-emitting insect repellent device shown in

[0013] Figure 3 is Figure 1 a bottom view of the light-emitting insect repellent device shown in

[0014] Figure 4 is a cross-sectional view of the light-emitting insect repellent device taken along line Figure 1 4-4.

[0015] Figure 5 is a cross-sectional view of the light-emitting insect repellent device taken along line Figure 1 5-5.

[0016] Figure 6 is Figure 4 and Figure 5 a perspective view of the battery housing shown in

[0017] Figure 7 is Figure 4 and Figure 5 an alternative perspective view of the battery housing shown in

[0018] Figure 8 is Figure 4 and Figure 5 a perspective view of the first side of the printed circuit board (PCB) shown in

[0019] Figure 9 is Figure 4 and Figure 5 a partially exploded perspective view of the second side of the PCB shown in

[0020] Figure 10 is Figure 1 、 Figure 2 and Figure 4 an exploded perspective view of the power button assembly shown in

[0021] Figure 11 a perspective view of the power button assembly before being assembled to the PCB.

[0022] Figure 12 is a front view of the reservoir according to the present invention.

[0023] Figure 13 is a perspective view of a second embodiment of the insect repellent device according to the present invention.

[0024] Figure 14 is a cross-sectional view of the insect repellent device taken along line Figure 13 14-14.

[0025] Figure 15 is an alternative cross-sectional view of the insect repellent device taken along Figure 13 line 14-14.

[0026] Figure 16 is Figure 13 the bottom view of the insect repellent device shown in

[0027] Figure 17 is Figure 14 and Figure 15 the exploded perspective view of the heater module shown in

[0028] Figure 18 is Figure 17 the perspective view of the heater module shown in

[0029] Figure 19 is along Figure 18 line 19-19 of the cross-sectional view of the heater module.

[0030] Figure 20 is Figures 13 to 15 the exploded perspective view of the cap assembly shown in

[0031] Figure 21 is Figure 20 the perspective view of the cap assembly shown in

[0032] Figure 22 is along Figure 21 line 22-22 of the cross-sectional view of the cap assembly.

[0033] Figure 23 is Figure 14 and Figure 15 the perspective view of the main PCB assembly shown in

[0034] Figure 24 is Figure 23 an alternative perspective view of the main PCB assembly shown in

[0035] Figure 25 is Figure 23 and Figure 24 the exploded perspective view of the main PCB assembly shown in

[0036] Figure 26 is Figure 14 and Figure 15 the perspective view of the base assembly shown in

[0037] Figure 27 is Figure 26 the exploded perspective view of the base assembly shown in, showing an alternative embodiment of the battery and the battery carrier.

[0038] Figure 28 is along Figure 26A cross-sectional view of the base assembly taken along line 28-28, showing an alternative embodiment of the battery and the battery carrier. DETAILED DESCRIPTION

[0039] Referring now to the drawings, Figures 1 to 12 a first embodiment of the light-emitting insect repellent 10 is illustrated. The illustrated light-emitting insect repellent 10 includes an insect repellent housing 11 having a base 12, a cover assembly 14, and a body assembly 13. The body assembly 132 includes a body portion 13A and a lighting panel 16 that defines a circumferentially extending sidewall of the light-emitting insect repellent 10. The lower surface of the base 12 includes a plurality of support feet 18. In the illustrated embodiment, the base 12 includes three support feet 18. However, it will be understood that the base 12 may have more than three support feet 18. In the illustrated embodiment, the lower surface of the base 12 further includes ventilation and discharge openings 20, as Figure 3 best shown in. Each component of the insect repellent housing 11 may be formed of any desired rigid plastic material, including but not limited to polypropylene, glass-filled polypropylene, polycarbonate, and hybrid polymers.

[0040] The base 12 further includes a lamp switch assembly 22 having a lamp switch 22A and a button 22B, where the button 22B is visible in Figures 1 to 3 . The base 12 further includes a status indicator lens 24, and portions of the status indicator lens (see circle 26) are selectively illuminated, as explained below, to indicate whether the power supply and heat in the light-emitting insect repellent 10 are operable, and other portions of the status indicator lens (see circle 28) are selectively illuminated to indicate the battery charge level. The on / off power button 23 is mounted within the status indicator lens 24 and is configured to engage an on / off power switch 52, as described below.

[0041] The cover assembly 14 includes a first or upper portion 15A and a second or lower portion 15B. The upper portion 15A includes an opening formed centrally therethrough, through which a generally cylindrical heater chimney 30 of the heater assembly 31 extends. A plurality of magnets 2 are mounted, such as by press fitting, into grooves in the inner surface of the lower portion 15B.

[0042] A reservoir holder 34 is formed centrally in the base 12 and is configured to hold a reservoir 40, as shown in Figure 12 . The reservoir 40 may be filled with an insect repellent material and includes a wick 42 that extends into the interior of the reservoir 40. When the reservoir 40 is located within the reservoir holder 34, the wick 42 extends outwardly into the heater 7. The liquid volatiles contained within the reservoir 40 are drawn out of the reservoir 40 by capillary action and reach the distal end of the wick 42. The wick 42 is heated within the heater 7, causing the liquid volatiles to evaporate. This process continues until the reservoir is empty.

[0043] In Figure 4 and Figure 5 The heater assembly 31, best shown in, includes a heater PCB 3 mounted between a first part or heater base 4 and a second part or heater housing 5, where the heater base 4 and the heater housing 5 are attached by any desired method, including but not limited to mechanical fasteners and snap connections. The heater base 4 and the heater housing 5 are formed of any desired rigid heat-resistant plastic, including but not limited to glass-filled nylon and other heat-resistant plastic materials. The heater base 4 includes three bosses or legs 6 extending outwardly from the lower surface of the heater base (downward when viewed in Figure 4 . The legs 6 engage with the magnet 2 and ensure that the magnet 2 remains disposed within a groove in the inner surface of the lower part 15B.

[0044] The generally cylindrical heater 7 is electrically connected to the heater PCB 3 via an electrical connector (not shown). The cylindrical resilient heater seal 8 is press-fit through an opening in the heater housing 5 and surrounds the first end of the heater 7 (the upper end when viewed in Figure 4 and Figure 5 . As shown in Figure 4 and Figure 5 , the heater assembly 31 is mounted within the lower part 15B of the cover assembly 14. The heater seal 8 can be formed of any desired flexible material, including but not limited to rubber and other heat-resistant elastomers compatible with liquid volatiles.

[0045] The base 12 includes a battery housing 32 configured for two batteries, such as for example two rechargeable lithium-ion batteries 33. Alternatively, the battery housing can be configured for one battery, or other power source. As shown in Figure 6 and Figure 7 , the battery housing 32 includes a cradle having a generally C-shaped battery mounting surface 74, and an array of reinforcing support ribs 76. Advantageously, the reinforcing support ribs 76 provide sufficient strength and stiffness to the battery housing 32 such that the battery housing will not be damaged even if accidentally dropped during use, and such that in some embodiments, including the embodiments shown in Figure 14 and Figure 15 , the insect repellent can be manufactured without a conventional foam pad that wraps the battery.

[0046] The mounting ring 44 includes a housing 46 for the power button assembly 64 and is mounted between the base 12 and the lighting panel 16.

[0047] The light diffuser panel 36 is mounted to the mounting ring 44 that surrounds the reservoir holder 34 and is located between the lighting panel 16 and the PCB 38. The PCB 38 is placed on the mounting posts on the upward-facing surface of the base 12, and the mounting ring 44 is placed on the upward-facing surface of the PCB 38. The light diffuser panel 36 is placed on the upward-facing surface of the mounting ring 44. Then, the light diffuser panel 36, the mounting ring 44, and the PCB 38 can be attached together with fasteners (e.g., screws). The lighting panel 16 can be a translucent panel, a colored panel, or a transparent panel.

[0048] The light-emitting insect repellent 10 uses an electric heating element within the heater assembly 31 to volatilize an insect repellent active ingredient, such as, for example, metofluthrin or a similar compound, to form an area with an insect-reduced or insect-free zone around the light-emitting insect repellent 10.

[0049] Now referring to Figure 8 and Figure 9 , the PCB 38 is shown and the PCB 38 includes six medium-power LEDs 48 mounted to the first or upper side of the PCB 38 for a lighting effect. Alternatively, the quality and power level of the LEDs can vary depending on the desired light intensity, light color, and light effect. For example, LED lights can be provided to provide effects such as strobing, pulsing, color changing, varying light intensity, and other light effects.

[0050] LEDs 50 are provided on the PCB 38 for illuminating the power and heat indicator lights 26 and the battery charge level indicator light 28 within the status indicator lens 24. In the illustrated embodiment, two LEDs 50 are mounted to the upper side of the PCB 38 (as shown in Figure 8 ), and five LEDs 50 are mounted to the second or lower side of the PCB 38 (as shown in Figure 9 ). An on / off power switch 52 is provided for moving the light-emitting insect repellent 10 between on and off settings, and portions of the on / off power switch 52 (see the power and heat indicator light 26) are selectively illuminated, as explained below, to indicate whether the power and heat in the light-emitting insect repellent 10 are operable, and other portions of the on / off power switch (see the battery charge level indicator light 28) are selectively illuminated to indicate the battery charge level. The PCB 38 includes mounting holes 54 for receiving attachment members such as screws or bolts, an opening 56 configured to receive the reservoir 40 and provide drainage for the light-emitting insect repellent 10, and a flying lead 62 for connecting to the heater PCB 3 of the heater assembly 31.

[0051] As shown in Figure 9 , the second or lower side of the PCB 38 includes a battery connector 58, a USB-C connector port 59, and a flying lead 60 for connecting to the lamp switch assembly 22.

[0052] Now referring to Figure 10 and Figure 11 ,the power button assembly is shown at 64. The power button assembly 64 includes a light tube cover 66, a pair of upper light tubes 68, five lower light tubes 70, and a light tube housing 72 in which the light tubes 68 and 70 are mounted. The light tube housing 72 is mounted within the light tube cover 66. The on / off power button 23 is mounted within the light tube housing 72, and the status indicator lens 24 is mounted to the outer surface of the light tube housing 72. The power button assembly 64 is attached to the PCB 38 around the on / off power switch 52 and is configured such that the on / off power button 23 engages the on / off power switch 52. As Figure 11 shown in, the power button assembly 64 can be attached by sliding the power button assembly 64 onto the PCB 38.

[0053] The lighting panel 16 projects light at the intensity selected by the user. The light diffuser panel 36 receives light radiated from a plurality of light sources, such as the LEDs 48, and sends a uniform (or substantially homogeneous) spectrum to the lighting panel 16. The light diffuser panel 36 generates spectral light waves output to the lighting panel 16 such that the light output of the lighting panel 16 is substantially the same or uniform along the entire surface of the lighting panel 16. Since the other components in the light-emitting insect repellent 10 besides the lighting panel 16 and the light diffuser panel 36 are opaque, the light output to the lighting panel 36 through the light diffuser panel 36 is clean and uniform for the user of the light-emitting insect repellent 10. The light diffuser panel 36 can be a translucent panel made of a polymer or glass material. In one embodiment, the polymer can be formed of, for example, polycarbonate, polyethylene, or polyolefin materials, but other materials can also be used.

[0054] The spectrum can include any desired one or more ranges of light wavelengths. In one embodiment, the light wavelengths generally lie within the visible spectrum. In yet another embodiment, the light wavelengths are characterized by a light temperature factor, such as light used for color intensity characterization defined on the Kelvin scale. It is known that many species of mosquitoes are attracted to light, and these species of mosquitoes can be attracted to products that include light. By relying on the spectrum to attract insects, several mosquito traps use light to improve the capture effect. However, not all mosquito species respond in the same way, and the effect of light on mosquito behavior varies by mosquito species. As a host-seeking cue, the attraction of light is not as great as that of carbon dioxide (CO2). However, the combination of light and CO2 generally produces a higher number of trapped mosquitoes than can be produced by using either variable alone. Therefore, assuming these devices operate near a person exhaling CO2, adding light will increase the attraction to local mosquitoes.

[0055] After better understanding this relationship, it is desirable to minimize the effect of adding or using light on attracting insects in the context of an insect repellent device. Certain wavelengths of light and / or certain colors of light have been studied to determine their relative attractiveness to different mosquito species. Studies have shown that light in the green range and the blue-violet range is relatively attractive to certain species of mosquitoes. The UV wavelength range has been shown to be widely attractive to various insects, not just mosquitoes. In contrast, colors in the red-yellow range do not significantly increase the mosquito-catching effectiveness of a trap, indicating that these colors do not become significant attractant factors when added to the device. Specifically, colors below approximately 3000 Kelvin generally minimize this effect. In one embodiment, the color temperature is below 2700 Kelvin.

[0056] When attempting to minimize the effect of light on mosquito attraction, the intensity of the light can also be considered. Studies have shown that increasing the light intensity linearly increases the capture rate of related mosquito traps that rely on attracting insects. In one embodiment of the illuminated insect repellent 10, the light intensity can be user-selectable, ranging from 100% or full light emission capacity based on the light source output to a low-intensity range (such as 20% of the maximum illumination intensity).

[0057] The illumination light source is mounted on a dispersed area of the PCB 38 so as to send the illumination light evenly to the diffuser panel without creating areas of significantly changed light intensity. To minimize the effect on the illumination effect and prevent shadows caused by electronic components in the illuminated area, the PCB 38 is horizontally oriented, or substantially parallel to the cover assembly 14. Due to the horizontal orientation of the PCB 38 and surface-mounted light sources (such as the LEDs 50 provided on the PCB 38 for illuminating the power and heat indicator lights 26 and the battery level indicator light 28), the light pipes 68 and 70 are used to transition the indicator illumination to the status indicator lens 24 and provide feedback on functionality to the consumer. The light pipes 68 and 70 include light input ends that are positioned near the status light sources (i.e., the LEDs 50), typically in a one-to-one correspondence. The light pipes 68 and 70 also include output ends that project the status light signal onto the status indicator lens 24 to alert the user of the operating status of the illuminated insect repellent 10.

[0058] Alternatively, the PCB 38 may include one or more LEDs 48 or other light sources mounted to the second or lower side of the PCB 38. The PCB 38 may be mounted at other locations within the light-emitting insect repellent 10, such as closer to the cover assembly 14 and such that the light from the LEDs 48 mounted on the lower side of the PCB 38 is directed downward to achieve an illumination effect. The PCB 38 may also include LEDs 48 mounted to its lower and upper sides. Additionally, the quality and power level of the LEDs may vary according to the desired light intensity, light color, and light effect. For example, LED lights may be provided to provide effects such as strobing, pulsing, color changing, varying light intensity, and other light effects.

[0059] The PCB 38 may have other shapes, configurations, positions, and orientations within the light-emitting insect repellent 10. For example, the PCB may be cylindrical, conical, or frustoconical and positioned around the reservoir holder 34 within the base 12.

[0060] To transition from the horizontally mounted LEDs 50 to the vertical indicator output in the status indicator lens 24, the light tubes 68 and 70 are configured to form a curved or angled path. In one embodiment, the light tubes 68 and 70 may be configured to project light at a 90-degree angle, but any other angle may be contemplated within the scope of the present invention. At a point approximately coinciding with the intersection of the horizontal and vertical paths, the sections 74 of each of the light tubes 68 and 70 are equally oriented with respect to the vertical and horizontal light paths. In one embodiment, the paths intersect at a right angle and the equal orientation is approximately 45 degrees, as Figure 10 shown. The angled sections are adjusted, such as by polishing or mirror coating, to reflect the incoming light rays to the output associated with the status indicator lens 24. To maximize light transmittance and minimize light leakage from other sources, an opaque housing shields and separates each light source from other light sources (such as the illumination lamp 48 or other status indicator lights such as the LEDs 50). In alternative embodiments, the light tubes 68 and 70 may each include a light gasket or light tube shield that extends from the input end of the light tube and surrounds each light tube interface. The light tubes 68 and 70 may also have a coating or outer surface that prevents light from entering at points along the light tubes 68 and 70.

[0061] It will be understood that the power button assembly 64 may not be provided with the light tubes 68 and 70, such that only the light tube cover 66 and the polished inner surface of the light tube are used to reflect light.

[0062] Now referring to Figures 13 to 28, which illustrates the insect repellent 110 of the second embodiment. The illustrated insect repellent is similar to the insect repellent of the first embodiment, but may not include the lighting panel 16 of the light-emitting insect repellent 10. However, it will be understood that if desired, the insect repellent 110 may include a lighting panel similar to the lighting panel 16. The illustrated embodiment of the insect repellent 110 includes an insect repellent housing 112, which includes a housing base assembly 113 having a base 114 and a main housing portion 116, and a two-part cap assembly 118 having a cap base 120 and a cap top 122. Each component of the insect repellent housing 112 may be formed of any desired rigid plastic material, including but not limited to polypropylene, glass-filled polypropylene, polycarbonate, and hybrid polymers.

[0063] The lower surface of the base 114 includes a plurality of support feet 124. In the illustrated embodiment, the base 114 includes three support feet 124. However, it will be understood that the base 114 may have more than three support feet 124. In the illustrated embodiment, the lower surface of the base 114 further includes a ventilation and discharge opening 126, and an electrical connection port 128 having a spring pin 130 therein and configured to be connected to an associated docking station (not shown), as Figure 16 shown.

[0064] The base 114 further includes a status indicator lens 132, a portion of which is selectively illuminated, as explained below, to indicate whether the power supply and heat in the insect repellent 110 are operable, and other portions of the status indicator lens are selectively illuminated to indicate the battery charge level. The on / off power button 134 is mounted within the status indicator lens 132 and is configured to engage an on / off power switch 136, as described below.

[0065] The cap top 122 of the cap assembly 118 includes an opening formed therein at the center, through which the generally cylindrical heater chimney 138 of the heater module 140 extends.

[0066] The base 114 includes a battery tray 142, which has a plurality of reinforcing support ribs 144 and is configured to support a battery 146 (such as a rechargeable lithium-ion battery). Although only one battery 146 is shown in the illustrated embodiment, it will be understood that the dimensions of the base 114 and the battery tray 142 may be designed and configured to support a battery (not shown). The insect repellent 110 may be manufactured without a conventional foam pad wrapped around the battery 146, as Figure 14 and Figure 15 shown. In Figure 27 and Figure 28 another embodiment of the insect repellent shown, a foam pad 148 is provided and may be wrapped around the battery 146.

[0067] The reservoir holder 150 is centrally formed in the main housing portion 116 and is configured to hold the reservoir 40, as Figure 12 shown. Figure 12 The reservoir 40 as shown in Figure 12 may be filled with an insect repellent material and include a wick 42 extending into the interior of the reservoir 40. When the reservoir 40 is located within the reservoir holder 150, the wick 42 extends outwardly into the heater 158. The liquid volatile contained within the reservoir 40 is drawn out of the reservoir 40 by capillary action and reaches the distal end of the wick 42. The wick 42 is heated within the heater 158, causing the liquid volatile to evaporate. This process continues until the reservoir is empty.

[0068] In Figures 16 to 18 best shown, the heater module 140 includes a heater PCB 152 mounted between a first portion or heater base 154 and a second portion or heater housing 156, where the heater base 154 and the heater housing 156 are attached via a snap connection.

[0069] The heater base 154 and the heater housing 156 are formed of any desired rigid heat-resistant plastic, including but not limited to glass-filled nylon and other heat-resistant plastic materials. The heater base 154 includes three bosses or legs 155 extending outwardly from the lower surface of the heater base 154 (downward when viewed in Figures 17 to 19 ). As described below, the legs 155 engage with the magnet 164 and ensure that the magnet 164 remains disposed within a groove in the inner surface of the cap base 120.

[0070] The heater PCB 152 includes a generally cylindrical heater 158 that is electrically connected to the heater PCB 152 via an electrical connector 160. A cylindrical resilient heater seal 162 is press-fitted through an opening in the heater housing 156 and surrounds the first end of the heater 158 (the upper end when viewed in Figures 17 to 19 ). As Figure 13 and Figure 14 shown, the heater module 140 is mounted within the cap base 120 of the cap assembly 118.

[0071] During the assembly of the heater module 140, the heater 158 is electrically connected to the heater PCB 152 via the electrical connector 160 to define a heater PCB assembly 153. The heater PCB assembly 153 is placed on the heater base 154. Then the heater housing 156 is placed onto the heater PCB assembly 153 and attached to the heater base 154 via a snap connection. Then the heater seal 162 is press-fitted through an opening in the heater housing 156 and surrounds the first end of the heater 158 (when viewed in Figures 17 to 19When viewed from the front, it is the upper end). The heater seal 162 can be formed of any desired flexible material, including but not limited to rubber and other heat-resistant elastomers compatible with liquid volatiles.

[0072] Then, the assembled heater module 140 can be installed within the cap assembly 118. As Figures 20 to 22 shown, a plurality of magnets 164 are installed (such as by press-fitting) into the grooves on the inner surface of the cap base 120. Then, the heater module 140 is centered and installed within the cap base 120 such that the legs 155 engage with the magnets 164. Then, the heater chimney 138 is attached to the heater seal 162, and then the cap top 122 is attached to the cap base 120 via a snap connection such that the heater chimney 138 extends outward from the opening formed centrally in the cap top 122.

[0073] Figures 23 to 25 Shown is the main PCB assembly 166 and a method of assembling the main PCB assembly 166. The illustrated embodiment of the main PCB assembly 166 includes a conventional PCB 168 which is vertically oriented, or substantially parallel to the longitudinal axis of the insect repellent 110. Spring pins 170 or other spring-loaded contact probes are mounted to the first end 168A of the PCB 168 (when viewed from Figures 23 to 25 the front, it is the upper end). The first side of the PCB 168 may include a microcontroller, other required functional electronic components, and an on / off power switch 136 having a post extending outwardly which is electrically mounted to the PCB 168 and is necessary for operating the insect repellent 110. A lighting source, such as an LED 50, is provided on the PCB 168 for illuminating the power and heat indicator lights (not shown) within the status indicator lens 132 and the battery charge level indicator light (not shown). For example, the insect repellent 110 may be provided with 7 LEDs 50, including four chasing LEDs 50 (i.e., the LEDs 50 that chase during the preheating of the heater module 140 and become constantly lit after the insect repellent 110 is turned on and preheated), and three LEDs 50 for indicating battery charging and battery status.

[0074] The main PCB assembly 166 further includes a status indicator lens 132, an on / off power switch 134, a spring 172 extending between the posts of the on / off power switch 136, a light tube subassembly 174, and a PCB mounting frame or bracket 176 having a PCB access opening 178 formed therethrough. The PCB mounting bracket 176 includes an electrical connector 180 mounted to its base 182. The electrical connector 180 includes extending outwardly from the first surface of the electrical connector 180 (when viewed from Figure 24 the front, downward, and in Figure 28The plurality of spring pins 130 that extend (best shown in Figure 24 ), and spring pin electrical leads 184 that extend from a second surface of the electrical connector 180 on the base 182 of the mounting bracket 176 (upward when viewed in

[0075] The light tube subassembly 174 includes a light tube housing 186 having a button opening 188 formed therein centrally, attachment arms 190 extending outward therefrom, and a plurality of light tubes 192. In the illustrated embodiment, eight light tubes 192 are shown, but it will be understood that the light tube subassembly 174 may include any desired number of light tubes 192. The light tube subassembly 174 is substantially similar to the light tubes 68 and 70 of the light-emitting insect repellent 10 described above with reference to the first embodiment.

[0076] As Figures 23 to 25 shown, a method of assembling the main PCB assembly 166 includes mounting components necessary to operate the insect repellent 110 (including, for example, a microcontroller, other required functional electronic components, and an on / off power switch 136 having posts extending outwardly) to the first side of the PCB 168. Mounting the electrical connector 180 to the base 182 of the PCB mounting bracket 176. Mounting the PCB 168 into a recess formed in the PCB mounting bracket 176. Connecting the spring pin electrical leads 184 from the electrical connector 180 on the base 182 of the mounting bracket 176 through the PCB into the opening 178 to the second side of the PCB 168.

[0077] Placing the spring pins 170 on the posts and heat-fusing the posts to lock the spring pins 170 in place at the first end 168A of the PCB 168. Then snapping the on / off power button 134 into the button opening 188 of the light tube housing 186. Attaching the spring 172 to the post of the on / off power switch 136, and snapping the attachment arms 190 of the light tube subassembly 174 into through holes in the PCB 168 to engage and snap onto the PCB mounting bracket 176, thereby attaching the light tube subassembly 174 to both the PCB 168 and the PCB mounting bracket 176 and compressing the spring 172. Then snapping the status indicator lens 132 onto the light tube subassembly 174, thereby defining the main PCB assembly 166.

[0078] Once the main PCB assembly 166 is assembled, the housing base assembly 113 can be assembled. To assemble the housing base assembly 113, the USB plug 194 is inserted into the USB-C connector port opening 196 in the housing base 114. The USB plug 194 can be formed of any desired resilient material, such as butyl rubber and other elastomers. Subsequently, the assembled PCB assembly 166 is inserted into the cavity 198 in the housing base 114. Then, the spring pins 130 of the electrical connector 180 of the PCB mounting bracket 176 are snapped into the electrical connection ports 128 in the housing base 114 to position the PCB assembly 166 within the insect repellent housing 112.

[0079] Advantageously, in addition to using the USB-C port opening 196, the spring pins 130 of the electrical connector 180 are also positioned and configured to dock or connect to a docking station (not shown) as an alternative method of charging the insect repellent 110.

[0080] The battery 146 is attached to the PCB assembly 166 and placed on the ribs 144 formed in the housing base 114 and defining the battery cradle 142. Then the main housing portion 116 is snapped onto the housing base 114 such that the spring pins 170 extend through slots in the pin ports 200 formed in the main housing portion 116. A plurality of snaps 202 are installed in the snap cavities 204 formed in the main housing portion 116. Then the cap assembly 118 is installed on the housing base assembly 113 such that the magnet 164 in the cap assembly 118 engages the surface of the snap 202 installed in the housing base assembly 113.

[0081] The principles and operating modes of the present invention have been explained and illustrated in its preferred embodiments. However, it must be understood that the present invention can be practiced in a manner different from that specifically explained and illustrated without departing from its spirit or scope.

Claims

1. A luminous insect repellent, comprising: a heater assembly; a power supply; an insect repellent power switch; and a power button assembly, the power button assembly including a status indicator lens, an insect repellent power button, and at least one light pipe, the at least one light pipe being optically connected to the status indicator lens and configured to project light from a light source onto the status indicator lens; wherein the insect repellent power switch is electrically connected between the power supply and the heater assembly.

2. The luminous insect repellent according to claim 1, further comprising a printed circuit board PCB, the PCB including a light source and being configured to control the operation of the heater assembly and generate a status signal from the output of the light source to the status indicator lens.

3. The luminous insect repellent according to claim 2, wherein the light source includes a plurality of first LEDs mounted on both sides of the PCB.

4. The luminous insect repellent according to claim 3, further comprising a housing configured to support the heater assembly, the power supply, and the PCB; wherein the housing includes a base, a lid, a lighting panel located between the base and the lid, and a light diffuser panel mounted within the housing between the lighting panel and the PCB; and wherein the PCB includes a plurality of second LEDs on its first side, the first side of the PCB facing the light diffuser panel.

5. The luminous insect repellent according to claim 4, wherein the plurality of second LEDs are controlled by a light switch to selectively control the output of the plurality of second LEDs, the output being between an off state and an illumination state, the illumination state being controllable between 100% brightness state of the plurality of second LEDs and 20% brightness state of the plurality of second LEDs.

6. The luminous insect repellent according to claim 5, wherein the PCB further includes an electrical connector that extends outwardly from an opening in the base and is configured to connect to a corresponding electrical connector in a docking station, the docking station being configured to supply power to the luminous insect repellent.

7. The luminous insect repellent according to claim 3, further comprising a housing configured to support the heater assembly, the power supply, and the PCB; wherein the housing includes a base, a lid, a lighting panel located between the base and the lid, and a light diffuser panel mounted within the housing between the lighting panel and the PCB; and wherein the power button assembly further includes a plurality of light pipes, the plurality of light pipes being optically connected to the status indicator lens and configured to project light from the plurality of first LEDs mounted on both sides of the PCB onto the status indicator lens at a certain angle.

8. The luminous insect repellent according to claim 7, wherein the power button assembly includes a light pipe cover, a plurality of upper light pipes, a plurality of lower light pipes, and a light pipe housing in which the light pipes are installed; wherein the light pipe housing is installed within the light pipe cover; wherein the insect repellent power button is installed within the light pipe housing, and the status indicator lens is mounted to the outer surface of the light pipe housing; wherein the power button assembly is attached to the PCB around the insect repellent power switch via a sliding connection between slots formed in the light pipe cover; and wherein the power button assembly is configured such that the insect repellent power button engages with the insect repellent power switch.

9. The light-emitting insect repellent device according to claim 8, wherein the lighting panel performs spectral light wave communication with the light diffuser panel; and wherein the light diffuser panel generates spectral light waves output to the lighting panel such that the light output of the lighting panel is substantially the same along the entire surface of the lighting panel.

10. The light-emitting insect repellent device according to claim 9, wherein the lighting panel is one of a translucent panel, a colored panel, and a transparent panel.

11. The light-emitting insect repellent device according to claim 7, wherein the base includes a battery housing configured to support at least one battery, and wherein the battery housing includes a bracket having a battery mounting surface and an array of reinforcing support ribs.

12. The light-emitting insect repellent device according to claim 1, wherein the at least one light pipe is optically connected to the status indicator lens and is configured to project light from the light source through a certain angle onto the status indicator lens.

13. A printed circuit board (PCB) assembly for an insect repellent device, comprising: a PCB mounting bracket having a base and a PCB access opening formed therethrough; a PCB having a first side and a second side, the PCB having a microcontroller, one or more functional electronic components, and a power switch having a power switch post extending outwardly, the power switch post being electrically mounted to the first side of the PCB and configured to operate the insect repellent device, the PCB being mounted in a groove formed in the PCB mounting bracket; a plurality of first spring pins mounted to the first end of the PCB; an electrical connector mounted to the base of the PCB mounting bracket, the electrical connector having a plurality of second spring pins and electrical leads extending from the electrical connector through the PCB access opening to the second side of the PCB; a light pipe subassembly including: a light pipe housing having a button opening formed therein centrally, an attachment arm extending outwardly therefrom, and a plurality of light pipes, the attachment arm extending through the PCB and into the PCB mounting bracket, a power button mounted in the button opening, a status indicator lens attached to the light pipe subassembly, and a spring mounted between the power switch post and the power button.

14. The PCB assembly according to claim 13, further comprising a plurality of light sources mounted to the first side of the PCB.

15. The PCB assembly according to claim 14, wherein the light source is an LED.

16. The PCB assembly according to claim 15, wherein the plurality of light pipes extend between the first side of the PCB and the status indicator lens, and the plurality of light pipes are configured to project light from the LED onto the status indicator lens.

17. The PCB assembly according to claim 16, wherein the PCB is mounted in an insect repellent device housing, the insect repellent device housing including a housing base assembly having a base and a main housing portion, and a two-part cap assembly having a cap base and a cap top.

18. The PCB assembly according to claim 17, wherein the insect repellent device housing further includes a heater assembly mounted in the cap assembly.

19. The PCB assembly according to claim 18, wherein the heater assembly includes A heater PCB, the heater PCB being mounted between a heater base and a heater housing, wherein the heater base and the heater housing are attached via a snap connection, and wherein the heater base includes three legs extending outwardly from the lower surface of the heater base; A cylindrical heater, the cylindrical heater being electrically connected to the heater PCB via an electrical connector; A cylindrical heater seal, the cylindrical heater seal being press-fitted circumferentially around the first end of the heater; And A heater chimney, the heater chimney being attached to the heater seal opposite the heater such that the heater chimney extends outwardly from an opening formed centrally in the cap top.

20. The PCB assembly according to claim 19, wherein the base includes a battery housing configured to support at least one battery, and wherein the battery housing includes a bracket having a battery mounting surface and an array of reinforcing support ribs.

21. The PCB assembly according to claim 20, wherein a second spring pin extends outwardly from an opening in the base and is configured to connect to a corresponding electrical connector in a docking station, the docking station being configured to supply power to a pest repeller in which the PCB assembly is installed.

22. A method of assembling a printed circuit board (PCB) assembly for a pest repeller, the method comprising: Mounting electrical components necessary for operating the pest repeller to a first side of the PCB, the electrical components including at least one of a microcontroller, one or more functional electronic components, and a power button having a power switch post extending outwardly, the power switch post being electrically mounted to the first side of the PCB and configured to operate the pest repeller; Placing a plurality of first spring pins on the post and heat-fusing the post to lock the plurality of spring pins in place at the first end of the PCB; Mounting an electrical connector to a base of a PCB mounting bracket, the electrical connector having a plurality of second spring pins and a spring pin electrical lead extending from the electrical connector; Mounting the PCB into a groove formed in the PCB mounting bracket and passing the spring pin electrical lead from the electrical connector on the base of the bracket through the PCB into an opening to connect to a second side of the PCB; Providing a light tube subassembly, the light tube subassembly including: a light tube housing having a button opening formed centrally therein, an attachment arm extending outwardly therefrom, and a plurality of light tubes, and snapping a push button into the button opening; Attaching a spring to the power switch post and passing the attachment arm of the light tube subassembly through the PCB and snapping it onto the PCB mounting bracket, thereby attaching the light tube subassembly to both the PCB and the PCB mounting bracket and compressing the spring; and Snapping a condition indicator lens onto the light tube subassembly, thereby defining the PCB assembly.

23. The method according to claim 22, wherein the first side of the PCB includes a plurality of LEDs.

24. The method according to claim 23, wherein the step of passing the attachment arm of the light tube subassembly through the PCB and snapping it onto the PCB mounting bracket further includes positioning the plurality of light tubes such that they extend between the plurality of LEDs and the condition indicator lens and are configured to project light from the plurality of LEDs onto the condition indicator lens.

25. The method according to claim 24 further includes mounting the PCB assembly in a part of the insect repellent housing.

26. The method according to claim 245, wherein the insect repellent housing includes a housing base assembly having a base and a main housing part, and a two-part cap assembly having a cap base and a cap top, and wherein the PCB assembly is mounted in the housing base assembly.

27. The method according to claim 26 further includes mounting a heater module in the cap assembly, wherein the heater module includes: a heater PCB mounted between a heater base and a heater housing, wherein the heater base and the heater housing are attached via a snap-fit connection, and wherein the heater base includes three legs extending outwardly from the lower surface of the heater base; a cylindrical heater electrically connected to the heater PCB via an electrical connector; a cylindrical heater seal circumferentially press-fitted around a first end of the heater; and a heater chimney attached to the heater seal opposite the heater such that the heater chimney extends outwardly from an opening formed centrally in the cap top.

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