LED modules and LED module assemblies

Abstract

The LED module 100 comprises one or more LED-LED cover pairs and a support member 106 (e.g., a PCB). Each pair comprises an LED 102 and an LED cover 104, separately mounted on the support member. For

Description

This invention relates to LED modules and LED module assemblies for use in a housing of an electronic input / output device, for example of the type used for electronic video games. BACKGROUND Electronic shooting games such as electronic clay target shooting games have grown increasingly popular due to their ability to provide immersive and realistic gaming experiences. One method to enhance this realism is to use deactivated real-life firearms, such as shotguns, as input / output devices (I / O devices). By integrating electronic components into these deactivated firearms, players can experience the tactile and visual feedback of handling an actual firearm while participatingin a virtual environment. There are various ways of setting up and operating an electronic shooting game system. One type of system uses cameras to track lights mounted onto an I / O device within a 3D space to determine the orientation of the I / O device in said space. As and when a user activates the I / O device within the 3D space, the system can determine its orientation to determine, for example, the trajectory of digital shotgun shot relative to a screen displaying a virtual gaming environment. A key component in modifying firearms into I / O devices for use in such electronic shootinggames employingthe aforementioned type of tracking system is the use of lightemitting diodes (hereafter “LEDs” or “diodes”) to assist the camera system with tracking the movement and orientation of the I / O device in a 3D space. These LEDs emit signals that can be captured by tracking systems including cameras or other sensors capable of sensing light emitted from the LEDs, allowing the game software to accurately register the I / O device’s position and direction. The tracking of the LEDs is crucial for creating a seamless interaction between the physical device and the virtual game world. Modifying a real-life shotgun into an I / O device for the purpose described above presents significant challenges. One challenge is the integration of LEDs into a barrel. To maintain the authentic appearance and feel of the I / O device as a firearm, it is advantageous to mount the LEDs from the inside of the barrel outward, and it is functionally important to do so on different upper sides of the barrel e.g. substantially between the 10 and 2 o’clock positions around the circumference of the barrel taking 12 o’clock to be the top of the barrel where the rib of the shotgun is arranged (so that the LEDs emit light from upper portions of the barrel for an overhead camera system to see, although the LEDs could alternatively be mounted in substantially lower positions e.g. 4 and 7 O’clock positions if cameras are to be mounted at a low level facing upwards instead) to enable the orientation to be determined by triangulation. Mounting from within the barrel in this way allows the electronic components to be hidden, preserving within the I / O device the gun’s external aesthetics. In the field of electronic devices, particularly those devices involving PCBs and LEDs, one common approach is to mount a diode directly onto the PCB. This approach allows for a compact and stable configuration, providing both electrical connections and mechanical support for the LEDs. However, in practice this often means that the LEDs are positioned away from the area where light is required. In many applications, it is necessary to direct the light emitted from LEDs to a specific location or out of an enclosed housing. To achieve this, a “lightpipe” is often used. A lightpipe is an optical component that guides or channels light from the LED to the desired location, e.g. ensuring that light is effectively transmitted out from the housing of an electrical device. Lightpipes are particularly useful in applications where space is limited or where precise light direction is required. By using a lightpipe, the design can maintain a sleek and compact form factor while ensuring optimal light output and visibility. When modifying a real-life shotgun into an I / O device as described above, to ensure that light emitted from LEDs secured to a PCB within the body of the shotgun turned I / O device is effectively emitted therefrom for the tracking system to pick-up, lightpipes can be used to transmit light from the LEDs. These lightpipes extend from the LEDs and may protrude from the surface of the barrel through precisely drilled holes. Typically, lightpipes are attached directly onto the LEDs, which are in turn mounted directly onto the PCBs. This direct attachment is key for efficient light transmission, as it minimises light loss and ensures that effective volumes of light emitted by the LED are captured and guided by the lightpipe. However, it has been found that using lightpipes in this way presents a significant reliability issue in applications where the device may be subjected to mechanical shocks or impacts, such as in portable or handheld devices like I / O devices (e.g. electronic guns). The primary problem with this approach is the mechanical stress exerted on the LED-PCB connection when the device is dropped or receives an impact. When the I / O device is dropped, the inertia of the PCB mass against the lightpipes, which are fixed in the precisely drilled holes, causes a force to be exerted on the LED-PCB connection. This force has been found to readily lead to failure of the LED itself or of the electrical connection between the LED and the PCB, or both. That is, the mechanical stress upon dropping the device can cause the LED to break or the solder joints holding the LED and PCB together to crack, resulting in device failure and necessitating repairs or replacements. This invention seeks to address these problems by providing a solution that mitigates the mechanical stress exerted on LEDs on an LED module utilising lightpipes, and enhances the overall durability and reliability of the electronic device. SUMMARY OF INVENTION According to a first aspect, there is provided an LED module for an electronic device housing, comprising: one or more LED-LED Cover Pairs and a support member, each of the one or more LED-LED Cover Pairs comprising an LED and an LED cover, wherein the LED and LED cover are mounted separately on the support member; wherein, for each LED-LED Cover Pair, the LED cover is configured to cover the LED while enabling the transmission of light emitted from the LED via a light transmission path defined by the LED cover, wherein the LED is positioned within a recess defined by the LED cover, and the LED cover is further configured to maintain a gap between the LED and the LED cover. Advantageously, the arrangement of the first aspect and the provision of a gap between the LED and LED cover both mounted separately onto the support member (i.e. preventing direct physical contact between the two parts mounted to the support member), ensures that any mechanical stresses, such as those caused by mechanical shock or external forces acting on the LED cover when engaged with an opening in the housing, are transmitted through to the support member rather than to the LED. This arrangement has been found to reduce the likelihood of damage to the LED, thereby enhancing the overall reliability and durability of the electronic device into which the LED module is installed. Furthermore, by isolating the LED from mechanical stresses, the invention minimises the risk of LED failure, extending the operational lifespan of the device and reducing maintenance costs associated with LED replacements. The term “LED module” is used herein to define a device capable of supporting one or more LEDs. The LED module is suitable for use in an electronic device housing in that it is configured to be inserted and used within an electronic device housing as an internal component thereof, and provide light emissions from the LED(s) through one or more openings in the housing which may be arranged (positioned) on said housing to correspond to the arrangement (position) of the LED(s) on the LED module. The housing and the openings drilled into the housing do not form part of the LED module of the first aspect, although a device comprising a housing with one or more openings and an at least one LED module in accordance with the first aspect is disclosed herein in relation to the third aspect. The term “light transmission path” refers to the trajectory through which light emitted by the LED travels, controlled by the shape and material properties of the LED cover. This path may influence the angle, diffusion and focus of the light emission. The housingfor use with the LED modules (and LED module assemblies) disclosed herein could be any housingfor an electronic device requiring insertion of LEDs for transmitting light through openings thereon, and generally comprises one or more external walls which define an interior space for housing at least LED modules / module assemblies. Optionally, the LED module is for an electronic I / O device or just an output device housing. The term "I / O device" refers to an electronic device that facilitates input and / or output operations, allowing the exchange of data between the device and external systems or users. Examples of I / O devices include, but are not limited to, keyboards, mice, displays, network interfaces, sensors, and game console controllers. I / O devices typically have a housing that accommodates various internal components, including in some cases LED modules. The LED module described herein may be for I / O devices which employ LED modules. The term "support member" refers to a structural component of the LED module that provides a mounting platform for the LED(s) and LED cover(s). This support member at least ensures that the LED(s) and LED cover(s) remain correctly positioned and securely attached relative to one another and any other LED-LED Cover Pairs during normal use, which may not be provided by a material with reduced structural integrity. The LEDs and LED Covers are “mounted” on the support member, and this means that they are at least mechanically connected to the support member and may optionally be electronically connected (in the case of the LEDs). While the LEDs require an electronic connection to at least a power source to operate, a power source / electronic connection does not need to be provided via the support member and could come from separate wires connected to a power source. Optionally, the LED Cover of each LED-LED Cover Pair comprises a base surface and a light emission surface. Optionally, the LED cover of each LED-LED Cover Pair comprises a protrusion portion. Optionally, the protrusion portion is arranged on the light emission surface. Optionally, the base surface and the light emission surface are on opposing sides of the LED Cover, and the base surface is configured to be adjacent the support member. Advantageously, this arrangement ensures that the light emission surface is oriented in a direction optimal for light transmission through the housing opening, enhancing light output efficiency. Optionally, the base surface defines the recess on the LED cover. Optionally, the LED cover of each LED-LED Cover Pair comprise a protrusion portion. Optionally, the LED cover of each LED-LED Cover Pair comprises a protrusion portion arranged on the light emission surface. Optionally, the protrusion portion is a domed shape or a truncated dome shape. Optionally, the protrusion portion forms at least part of the light transmission path. Optionally, the protrusion portion is configured to be secured within a correspondingly sized opening of an electronic device housing, thereby enabling the LED module to be secured in a fixed position with respect to said housing at the location of said LED-LED Cover Pair. Optionally, the electronic device housing comprises one or more walls which define a cavity and one or more openings, and wherein at least one of the LED-LED Cover Pairs further comprises a biasing member configured to be compressed against a wall of the housing and, when compressed, exert and maintain a counterforce against the wall and the support member in a direction opposed to the compression, said biasing member being configured so that said counterforce: pushes at least one of the LED cover protrusion and the support member against a wall of the housing, thereby arranging the LED to a position suitable for emitting light via one of the one or more openings, and pushes the protrusion at least partially into one of the one or more openings, thereby supporting and holding the LED module within the cavity. Advantageously, the biasing member ensures a firm fit of the LED module within a housing, reducing risk of the module shifting during operation and thus maintaining alignment with the housing openings for consistent light output. Optionally, the LED cover of each LED-LED Cover Pair comprises a support surface, said support surface being shaped to match the profile of the wall of the housing it is configured to be pushed up against. Optionally, the one or more LED covers comprise a material selected from the group consisting of acrylic, polycarbonate, glass, polystyrene (PS), poly(methyl methacrylate) (PMMA), polyurethane, polyetherimide (PEI), polyethylene terephthalate (PET), and cyclic olefin copolymer (COC), preferably the LED covers are made from a material selected from the group consisting of acrylic and polycarbonate. Advantageously, these materials offer durability and light transmission efficiency. Optionally, the LED and LED cover of each LED-LED Cover Pair are mounted on the support member independently. Optionally, at least one of the LED and the LED cover of each LED-LED Cover Pair are mounted on the support member by adhesive. Optionally, at least one of the LED and the LED cover of each LED-LED Cover Pair comprise one or more pins configured to fit within corresponding openings provided on the support member, thereby enabling the mounting of the LED and / or LED cover onto the support member. Optionally, the LED cover on each of the LED-LED Cover Pairs comprises one or more pins on the base surface, said pins being configured to fit within corresponding openings provided on the support member, thereby enabling the mounting of the LED cover onto the support member. Optionally, the support member is a printed circuit board (PCB). Optionally, the printed circuit board is a flexible printed circuit board (FPCB) thereby allowing for flexible mounting configurations. Optionally, the gap between the LED and LED cover recess is from 0.1 to 2 mm, preferably 0.2 to 1 mm, most preferably 0.5 mm. Preferably, this gap distance is the distance between the top of the LED and an opposing surface of the recess. Optionally, the gap between the LED and the LED cover recess is filled with an optical grade material selected from the group consisting of optical grade silicon, high-purity silicone, optical grade epoxy, optical grade acrylic, optical grade polyurethane, optical grade silicone gel, and optical adhesives. Optionally, the LED cover of each LED-LED Cover Pair are configured to provide a waterproof or dustproof seal around the one or more LEDs. Optionally, the LED cover of each LED-LED Cover Pair is configured to diffuse light emitted by the LED. It is intended that the features described above as optional may be combined with the features of the first aspect in any combination. According to a second aspect, there is provided an LED module assembly comprising more than one of the LED modules as defined herein in relation to the first aspect. Optionally, the LED module assembly comprises two LED modules as defined herein in relation to the first aspect, wherein the support member on each LED module comprises one or more notches and one or more projections arranged along one edge, the notches and projections of one LED module configured to interlock with the projections and notches respectively from the other LED module, thereby configuring the two LED modules to interlock. Optionally, the LED-LED Cover Pairs (including the biasing members if provided) are arranged on the one or more projections. Optionally, the biasing members (if provided) comprise a spring or a resilient material such as foam. Optionally, the biasing members (if provided) comprises a spring such as a leaf spring. Optionally, the leaf spring is a dual leaf spring assembly comprising a first leaf spring and a second leaf spring mounted in opposition to the first leaf spring, for example to form an oval shape. The optional one or more notches and one or more projections arranged along one edge - and the corresponding further optional features tied to the notches and projections -may be applied to the support member of the first aspect. According to a third aspect, there is provided an electronic device comprising: a housing comprising one or more walls which define a cavity and one or more openings; and at least one LED module as defined herein in relation to the first aspect, or an LED module assembly as defined herein in relation to the second aspect, wherein the at least one LED module or LED module assembly is positioned within the housing and configured so that light emitted from the LED(s) passes through the one or more openings. The housing which is part of the electronic device of the first aspect being the housing referred to in relation to (but not forming part of) the first and second aspects. Optionally, the housing is cylindrical, and preferably the housing is a barrel of a shotgun. Optionally, the electrical device further comprises a power source located within the housing for providing power to the LEDs of the LED-LED Cover Pairs. BRIEF DESCRIPTION OF DRAWINGS The above and other aspects of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a side cross-section of an LED module in accordance with this disclosure. Figure 2 shows a side view of the LED module shown in cross-section in Figure 1. Figures shows a perspective view of an LED assembly in accordance with this disclosure. Figure 4 shows a zoomed in perspective view of the LED assembly show in Figure 3. DETAILED DESCRIPTION The present disclosure relates to LED modules and LED module assemblies both for use within the housing of an electronic device such as an I / O device or an output only device. A ‘housing’ as used in this context is a part of an electronic device which contains the electronic components (or at least some electronic components) of said device, such as printed circuit boards, batteries, sensors, etc. The housing could take any form depending on the intended use, for example the housing could be the barrel of a deactivated shotgun which is adapted for an electronic shooting game where the barrel forms an interior space (the housing). Alternatively, the housing could be, for example, a computer / console game controller of any kind or devices for use with electronic games such as magic wands, musical instruments, imitation weapons of any kind such as hammers, axes, firearms or the like. The housing could alternatively be the housing of a remote controller device. The LED modules and LED module assemblies disclosed herein address the problems defined above. The invention will now be described at first with reference to the accompanying Figures 1 and 2, which illustrate an exemplary embodiment of the LED module according to the present disclosure. It should be noted that the features of the invention are not limited to this particularembodimentwhich is exemplary, and theskilled person will recognise that modifications to this example embodiment can be made while remaining within the scope of the invention. Figures 1 and 2 illustrate a portion of an LED module 100 for use within a housing of an electronic input / output (I / O) device, such as those employed in electronic gaming systems, particularly for use with modified firearms like deactivated shotguns used in virtual target shooting games. A whole LED module substantially corresponding to LED module 100 is shown in Figures 3 and 4 separately at items 100a and 100b (which together make up an LED module assembly) although LED modules 100a and 100b further comprise notches and projections as described below which, while advantageous for certain applications, are not present on LED module 100 and are not essential to the invention described herein. The LED module 100 comprises one or more LED-LED Cover Pairs (the Figures only show a single LED-LED Cover Pair), each one comprising an LED 102 and an LED Cover 104, and a support member 106 which is a printed circuit board (PCB) that provides mechanical support and proper alignment for the LEDs 102 and their associated covers 104. The LED module in accordance with this disclosure may comprise any number of LED-LED Cover Pairs, as required by the intended use. The LED 102 is positioned within a recess 110 defined by the LED cover 104, and a gap 112 is maintained between the LED 106 and the cover 104. This gap, together with the separate (independent) connection / mounting of the LED and LED cover to the support member 106, serves to isolate the LED 102 from direct physical contact with the cover 104, reducing the transmission of mechanical stresses that could otherwise damage the LED or its electrical connections during use. The support member 106 is a PCB and provides a structural platform onto which both the LED 102 and the LED cover 104 are mounted. It ensures that once the various components are attached thereto they remain in substantially constant relative positions to each other when in normal use and when being inserted into the housing. The PCB 106 is configured to be inserted into the interior of the housing and aligned by way of its dimensions and its attachment points to the LED-LED Cover Pairs such thatthe LED(s) 102 and LED covers 104 (and their protrusions 114) align with one or more openings provided in the external wall of the housing. The support member 106 may take the form of a printed circuit board (PCB) as shown in the Figures or, in some embodiments, a flexible printed circuit board (FPCB) to allow for flexible mounting configurations within the housing. Alternatively, the support member 106 does not need to be a PCB and may alternatively be other support members made from any suitable material such as polymeric material, metal, or composite material, without a printed circuit board aspect to provide an electrical connection to the LED(s). If the support members is not a PCB then the LED(s) may be connected to an electronic circuit and a power source by wired connection. The shape of the PCB 106 is substantially strip like. That is, PCB 106 is a strip in that it is narrow and thin. The elongated sections of PCB 106 are configured to accommodate and support the various components of the LED module 100. A strip shape is suitable for use where the housing the module is to be inserted is long and narrow (e.g. the barrel of a gun) however the shape / dimensions of the PCB 106 are not limited to only being strip like and may be other dimensions, e.g. rectangular or circular, depending on the shape of the housingthe module 100 is to be used within orthe arrangement of the LEDs. For example, if the housing the LED module 100 is to be used within is cylindrical (or any other shape for that matter) then the dimensions of the PCB 106 should be selected to enable the LED(s) 102 / LED cover(s) 104 to be aligned with (and optionally inserted into) one or more openings in the housing with the optional assistance of biasing means 120 (i.e. the dimensions of the PCB should not prevent the LED(s) 102 / LED cover(s) 104 from being aligned with and inserted into the openings in the housing. The PCB 106 may be configured so that the LED module 100 may castellate with other LED modules in accordance with this disclosure, an example of which is disclosed below in relation to Figures 3 and 4. The LED cover 104 of each LED-LED Cover Pair is configured to enclose the LED 102 in combination with the support member (PCB) 106 which the LED 102 sits / is mounted on, while allowing the light emitted from the LED 102 to be transmitted through a light transmission path defined by the LED cover 104. The LED cover 104 of LED module 100 includes a base surface. When the LED cover 104 is mounted to the PCB 106 the base surface sits adjacent to the PCB surface. The LED cover 104 also has a light emission surface which is on an opposing side of the LED cover 104 facing outwards from the LED module 100 in the general direction that light is to be emitted, and configured so that when the LED module 100 is inserted into a housing for an electronic device the LED cover 104 aligns with the opening(s) in the housing, thereby enabling the transmission of light out from said opening(s). As shown in Figures 1 and 2, the LED cover 104 further comprises a protrusion portion 114 on the light emission surface. This protrusion 114 is a truncated dome shape, which assists in guiding the light from the LED 106 through the opening in the housing. The protrusion 114 is configured to extend outward from the LED cover and LED module 100 generally, to fit snugly into a correspondingly sized opening in the housing, thereby securing the LED module 100 in a fixed position at that point relative to the housing and enabling light emitted from the LED to be effectively be transmitted from the LED module 100 to the outside of the housing. The LED cover 104 comprises two pins 116 (which may alternatively be referred to as protrusions or attachment pins) only one of which is labelled on Figure 1, which fit snugly into corresponding holes arranged on the PCB 106 thereby enabling the LED cover 104 to be mounted securely to the PCB 106. The pins 116 transfer mechanical shock from the LED 104 to the PCB 106. This mounting connection may be supplemented by adhesive or the pinsl 16 may be replaced with adhesive instead. The LED cover 104 is provided with a surface that matches the profile of the housing wall against which the LED cover 104 will be pushed up against when inserted into the housing, ensuring a stable connection between the housing and the LED module 100. The gap 112 between the LED 102 and the recess 110 of the LED cover 104 serves to prevent direct contact between the LED cover and LED, and in turn allows for the absorption and dissipation of mechanical stresses that may be exerted on the LED cover 104 during operation onto the PCB 106 rather than onto the LED 102. By isolating the LED 102 from such stresses, the risk of damage to the LED 102 or failure of the electrical connection is greatly reduced, enhancingthe durability and reliability of the LED module 100. The distance between the top of the LED 102 and the opposing surface of the recess 100 is from 0.1 to 2 mm, preferably 0.2 to 1 mm, most preferably 0.5 mm. Depending on the shape of the LED 102 with respect to the shape of recess 100 the gap 112 may not be of a consistent distance. Optionally, the shape of the LED 102 and of the recess 100 may be configured so that the gap 112 is of consistent distance. In some embodiments, as illustrated in Figures 1 and 2, the LED module 100 may further comprise a biasing member 120. The biasing member 120 is a dual leaf spring each mounted in opposition. When compressed during insertion of the LED module into the housing, the biasing member 120 is configured to exert a counterforce against both the support member 106 and the wall of the housing. This counterforce is configured to push the LED cover 104 into a stable position within the housing, allowing proper alignment of the LED cover 104 with an opening on the housing for optimal light emission, pushing the protrusions 114 on the LED cover 104 into a corresponding opening on the housing. The biasing member 120 also serves to cushion any mechanical shocks, further reducingthe likelihood of damage to the LED module 100. Biasing members may not be required if the LED module is to be received by other forms of support within the housing, e.g. by rails or grooves. The LED cover 104 may be made from a variety of materials, including but not limited to acrylic, polycarbonate, glass, or optical-grade plastics such as poly(methyl methacrylate) (PMMA). The selection of material is dependent on the specific application, with considerations for light transmission efficiency, durability, and environmental resistance. In some embodiments, the LED cover 104 may be configured to provide a waterproof or dustproof seal around the LED 102, further enhancing the robustness of the LED module 100. An LED module assembly as described herein refers to an assembly comprising more than one of the LED modules of this disclosure, e.g. 2,3,4,5, 6 etc LED modules. Figures 3 and 4 show an exemplary embodiment of an LED module assembly comp rising two LED modules. The example LED module assembly of Figures 3 and 4 is shown generally at item 300, and comprises two LED modules 100a,100b, each LED module being in accordance with this disclosure and as discussed above in relation to Figures 1 and 2. Figures 3 and 4 show substantially the same LED module assembly 300, Figure 3 showing the entire assembly and Figure 4 showing a zoomed in view. Hereafter, when describing Figures 3 and 4 a letter ‘a’ will be used in relation to reference numbers denoting features of a first LED module 100a, and a letter ‘b’ will be used in relation to reference numbers denoting features of a second LED module 100b. The same numbering convention as used in relation to LED module 100 is used in Figures 3 and 4to describe like features of LED modules 100a and 100b. LED modules 100a and 100b incorporate the same features as LED module 100 and these shall not be repeated here when discussing LED module assembly 300. PCB 106a comprises 5 notches 308a and 6 projections 310a, which castellate (interlock) with 6 projections 310b and 5 notches 308b respectively of PCB 106b. The castellation of the PCBs 106a,106b within the PCB module assembly 300 means that the LEDs 102a from module 100a can be mounted at different angles with respect to LEDs 102b from module 100b. The castellation of the PCBs 106a,106b shown in Figures 3 and 4 enables the LEDs on PCB 106a to sit at 90 degrees (or any other angle) with respect to the LEDs on PCB 106b while the PCBs 106a,106b are castellated together. A castellated (interlocked) relationship between the two PCBs 106a,106b means that when the modules 100a,100b are castellated together and inserted into a housing the LEDs are kept in substantially the same position with respect to each other. This is important so that all of the LEDs 102a,102b become aligned with the openings of the housing simultaneously. The notches 308a,308b may optionally be longer than the projections 310a,310b as shown in Figures 3 and 4 and this enables the PCBs 106a,106b to slide to some extent with respect to each other, advantageously enabling the assembly to have tolerance for imprecisions in the positioning of the openings of the housing, or for the same LED module assembly to be used with housings of variations in arrangements of the holes. The castellated relationship between the two PCBs 106a,106b also means that when the LEDs 102a,102b are aligned with the openings of the housing simultaneously and are either pushed into said openings by the biasing member 120 (or other means such as into rails built into the housing which allows the PCBs 106a,106b to be slotted into the housing in the correct position), the castellations enable the PCBs 106a, 106b freedom of movement with respect to each other to move apart in order to allow the LEDs / LED covers 104a,104b to be pushed into said openings. Optionally, the side surfaces of the notches 308a,308b and which may also be called ‘castellation contact surfaces’ may be angled so as to preferentially cause the two LED modules 100a, 100b to be at a specific angle with respect to each other when castellated together and pushed up against each other. For small housings such as the substantially cylindrical barrel of a shotgun, the castellated relationship advantageously allows two (or more) LED modules to fit within the housing with the LEDs on each of the LED modules angled with respectto each other (e.g. at 90 degrees to each other) when without the castellations it would not be possible to do so given in order for each of the LED modules to be inserted properly the planes of each would need to intersect. The castellations (the notches 308a,308b and projections 310a,310b) allow the PCBs 106a,106b to pass through each other so that the LED modules 100a, 100b can work together even in small and confined housings. The castellation of the PCBs 106a,106b, provided by the notches 308a,308b and projections 310a,310b, allows for flexible and precise positioning of the LED modules 100a,100b within a narrow and long housing. As mentioned above, this interlocking mechanism, or castellation, allows the PCBs 106a,106b to be arranged at various angles relative to each other while being interlocked. This flexibility is particularly advantageous in applications such as mounting LEDs within a cylindrical housing, like a gun barrel, where space is tight and LEDs need to emit light from holes / openings of a housing at different angles, but could also be used effectively in housings of other shapes such as rectangular housings. A significant advantage of this castellated configuration for gun barrels is that it allows the LEDs to emit light through drilled holes on either side of the barrel. Furthermore, the castellation feature enhances the stability and structural integrity of the LED module assembly (300). The way the PCBs castellate can be configured to form a customised assembly for various housing shapes and sizes, and desired directions for LEDs, making it a versatile solution for different types of electronic I / O devices. In summary, the castellated design of the PCBs 106a, 106b allows for adjustable angling of the LED modules 100a,100b with respect to each other, enabling precise positioning of the LEDs / LED covers (the LED-LED Cover Pairs) within housings (e.g. cylindrical housing) to assist with inserting an LED assembly therein. The LED modules 100a,100b each comprise 6 LEDs which are each arranged on the projections 310a,310b and evenly spaced out along the length of the PCBs 106a,106b. Each projection 310a,310b has one LED mounted thereto. The relative sizes of the projections 310a,310b and / or the spacings between the LEDs / LED covers (the LED-LED Cover Pairs) on said protrusions 310a,310b may be adjusted and configured so that the LEDs / LED covers (the LED-LED Cover Pairs) arranged on the protrusions 310a,310b along the length of the PCBs 106a,106b are in a spaced apart arrangement with some LEDs / LED covers being closer to neighbouring LEDs / LED covers than others (i.e. the arrangement may provide for varying density of LEDs / LED covers arranged along the length of the PCBs. This enables the LED modules 100a,100b to provide constellations of different LED patterns / shapes instead of the spacings being uniform between all LEDs along the length of the PCB 106a,106b. Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, mean “including but not limited to”, and are not intended to (and do not) exclude other components. 5 It will be appreciated that variations to the foregoing embodiments of the invention can be made while still falling within the scope of the invention. Each feature disclosed in this specification, unless stated otherwise, may be replaced by alternative features serving the same, equivalent or similar purpose. Thus, unless stated otherwise, each feature disclosed is one example only of a generic series of equivalent features. 10 All of the features disclosed in this specification may be combined in any combination, expect combinations where at least some of such features and / or steps are mutually exclusive. In particular, the preferred features of the invention are applicable to all aspects of the invention and may be used in any combination. Likewise, features described in non-essential combinations may be used separately (not in combination). 15 It will be appreciated that many of the features described above, particularly of the preferred embodiments, are inventive in their own right and not just as part of an embodiment of the present invention. Independent protection may be sought for these features in addition to or alternative to any invention presently claimed.

Claims

1. An LED module for an electronic device housing, comprising:one or more LED-LED Cover Pairs and a support member, each of the one or more LED-LED Cover Pairs comprising an LED and an LED cover, wherein the LED and LED cover are separately mounted on the support member;wherein, for each LED-LED Cover Pair, the LED cover is configured to cover the LED while enabling the transmission of light emitted from the LED via a light transmission path defined by the LED cover,wherein the LED is positioned within a recess defined by the LED cover, and the LED cover is further configured to maintain a gap between the LED and the LED cover.

2. The LED module according to claim 1, wherein the LED Cover of each LED-LED Cover Pair comprises a base surface and a light emission surface.

3. The LED module according to claim 2, wherein the base surface and the light emission surface are on opposing sides of the LED Cover, and the base surface is configured to be adjacent the support member.

4. The LED module according to one of claim 2 or claim 3, wherein the base surface defines the recess on the LED cover.

5. The LED module according to any preceding claim, wherein the LED cover of each LED-LED Cover Pair comprise a protrusion portion.

6. The LED module according to one of claim 3 or claim 4 when dependent upon claim 2, wherein the LED cover of each LED-LED Cover Pair comprise a protrusion portion arranged on the light emission surface.

7. The LED module according to one of claim 5 or claim 6, wherein the protrusion portion is a domed shape or a truncated dome shape.

8. The LED module accordingto one of claims 5 to 7, wherein the protrusion portion forms at least part of the light transmission path.

9. The LED module accordingto one of claims 5 to 8, wherein the protrusion portion is configured to be secured within a correspondingly sized opening of an electronic device housing.

10. The LED module according to claim 9, wherein the electronic device housing comprises one or more walls which define a cavity and one or more openings, and wherein at least one of the LED-LED Cover Pairs further comprises a biasing member configured to be compressed against a wall of the housing and, when compressed, exert and maintain a counterforce against the wall and the support member in a direction opposed to the compression, said biasing member being configured so that said counterforce:pushes at least one of the LED cover protrusions and the support member against a wall of the housing, thereby arranging the LED to a position suitable for emitting light via one of the one or more openings, andpushes the protrusion at least partially into one of the one or more openings,thereby supporting and holding the LED module within the cavity.

11. The LED module according to claim 10, wherein the LED cover of each LED-LED Cover Pair each comprise a support surface, said support surface being shaped to match the profile of the wall of the housing it is configured to be pushed up against.

12. The LED module according to any preceding claim, wherein the one or more LED covers comprise a material selected from the group consisting of acrylic, polycarbonate, glass, polystyrene (PS), poly(methyl methacrylate) (PMMA), polyurethane, polyetherimide (PEI), polyethylene terephthalate (PET), and cyclicolefin copolymer (COC), preferably the LED covers are made from a material selected from the group consisting of acrylic and polycarbonate.

13. The LED module according to any preceding claim, wherein at least one of the LED and the LED cover of each LED-LED Cover Pair are mounted on the support member by adhesive.

14. The LED module according to any preceding claim, wherein at least one of the LED and the LED cover of each LED-LED Cover Pair comprise one or more pins configured to fit within corresponding openings provided on the support member, thereby enabling the mounting of the LED and / or LED cover onto the support member.

15. The LED module according to any preceding claim, wherein the support member is a printed circuit board (PCB).

16. The LED module according to claim 15, wherein the printed circuit board is a flexible printed circuit board (FPCB).

17. The LED module according to any preceding claim, wherein the gap between the LED and LED cover recess is from 0.1 to 2 mm, preferably 0.2 to 1 mm, most preferably 0.5 mm.

18. The LED module according to any preceding claim, wherein the gap between the LED and the LED cover recess is filled with an optical grade material selected from the group consisting of optical grade silicon, high-purity silicone, optical grade epoxy, optical grade acrylic, optical grade polyurethane, optical grade silicone gel, and optical adhesives.

19. The LED module according to any preceding claim, wherein the LED cover of each LED-LED Cover Pair are configured to provide a waterproof or dustproof seal around the one or more LEDs.

20. The LED module according to any preceding claim, wherein the LED cover of each LED-LED Cover Pair is configured to diffuse light emitted by the LED.

21. A LED module assembly comprising more than one of the LED modules according to any one of claims 1 to 20.

22. The LED module assembly according to claim 21, comprising two LED modules accordingto any one of claims 1 to 20, wherein the support member on each LED module comprises one or more notches and one or more projections arranged along one edge, the notches and projections of one LED module configured to interlock with the projections and notches respectively from the other LED module, thereby configuring the two LED modules to interlock.

23. An electronic device comprising:a housing comprising one or more walls which define a cavity and one or more openings; andat least one LED module in accordance with any one of claims 1 to 20 or an LED module assembly in accordance with claim 21 or claim 22, wherein the at least one LED module or LED module assembly is positioned within the housing and configured so that light emitted from the LED(s) passes through the one or more openings.

24. The electronic device according to claim 23, wherein the housing is cylindrical, and preferably the housing is a barrel of a shotgun.

25. The electronic device according to one of claims 23 or claim 24, further comprising a power source located within the housing for providing power to the LEDs of the LED-LED Cover Pairs.s

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