Light emitting diode (LED) assembly with curved printed circuit board (PCB)

Abstract

A light emitting diode (LED) assembly, includes a housing and a curved printed circuit board (PCB). The PCB includes a composite substrate formed from epoxy resin and glass fabric. A first LED is mounted to a first region of the PCB, and a second LED is mounted to a second region of the PCB. An intermediate region of the PCB joins the first region and the second region. The first region and the second region are flat and the intermediate region is curved. The LEDs each point in a different direction angle, due to the different angled planes of the first region and the second region.

Description

Docket No. 2024-1140 (S122995 1090WO)LIGHT EMITTING DIODE (LED) ASSEMBLY WITH CURVED PRINTED CIRCUIT BOARD (PCB)CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 789,347, filed on April 15, 2025, titled LIGHT EMITTING DIODE (LED) ASSEMBLY WITH CURVED PRINTED CIRCUIT BOARD (PCB).INCORPORATION BY REFERENCE

[0002] The disclosure of U.S. Provisional Patent Application No. 63 / 789,347, filed on April 15. 2025, titled LIGHT EMITTING DIODE (LED) ASSEMBLY WITH CURVED PRINTED CIRCUIT BOARD (PCB). is hereby incorporated by reference for all purposes as if set forth in its entirety.TECHNICAL FIELD

[0003] The present application relates to a light emitting diode (LED) assembly, and in particular, to an LED assembly with a curved printed circuit board (PCB).BACKGROUND

[0004] Power tools are electrically powered devices designed to make manual tasks easier and more efficient. Power tools can be corded or cordless (e.g.. powered by a built-in battery). Power tools are used in a variety of applications such as. for example, construction, woodworking, metalworking, home maintenance and repair. Common power tools include drills, saws, sanders, multi -tools, and grinders. Power tools offer a range of functions depending on the job. Compared to traditional unpowered tools, they reduce the physical effort required for tasks, increase precision, and speed up work. Proper visibilityDocket No. 2024-1140 (S122995 1090WO)and lighting is important when using power tools, especially in view of their power and speed, to reduce the risk of unwanted damage to a work piece or general harm.SUMMARY

[0005] In an aspect of the present disclosure, a power tool is disclosed. The power tool may comprise a tool housing and a light emitting diode (LED) assembly at least partially received in an interior of the tool housing the LED assembly. The LED assembly includes an LED assembly housing, and a printed circuit board (PCB) located within an interior of the LED assembly housing.

[0006] The PCB comprises a composite substrate comprising epoxy resin and glass fabric, a first LED mounted to a first region of the composite substrate, and a second LED mounted to a second region of the composite substrate. An intermediate region of the composite substrate joins the first region and the second region. The first region and the second region are arranged in a flat configuration and the intermediate region is arranged in a curved configuration relative to the first region and the second region. A metal layer is fixed to the PCB, and is electrically coupled to the first LED and to the second LED.

[0007] In an embodiment, the intermediate region comprises a width that is less than a width of the first region and of the second region. The reduced width may promote a controlled bending of the intermediate region to take its curved shape.

[0008] In an embodiment, a ratio of a length of the intermediate region to a thickness of the PCB is at least 15:1, or at least 20:1, or at least 23:1. Additionally, or alternatively, a thickness of the PCB is less than or equal to .6 mm, or less than or equal to .5 mm, or less than or equal to .4 mm. The reduced thickness of the PCB and dimension ratios may promote a controlled bending of the intermediate region to help the PCB take its curved shape.Docket No. 2024-1140 (S122995 1090WO)

[0009] In an embodiment, the metal layer that is deposited in the first region and in the second region occupies at least 60%, or at least 70%, or at least 85%, or at least 95% of the first region and the second region. This metal layer may be unbroken (e g., a solid plane) and serve as a stiffening support that holds the first region and second region flat under a flexing force which may be applied by the housing. In contrast, the metal layer in the intermediate region may be limited to the necessary traces carry ing current to or from the LED, to reduce the amount of metal in the intermediate region and promote the intermediate region to take the curved shape under the flexing force applied by the housing.

[0010] In an embodiment, the PCB further comprises a third LED mounted to a third region of the PCB, and a second intermediate region is located between the first region of the PCB and the second region of the PCB, wherein the third region of the PCB is flat and the second intermediate region is curved. More generally, the LED assembly may comprise two or more LEDs, each mounted to respective flat regions of the PCB, which may each be joined by respective curved intermediate regions.

[0011] In an embodiment, an illumination area of the LED assembly comprises at least a 120 degree radius. For example, the PCB may comprise three LEDs arranged along a length of PCB, each oriented in a different angle, to cover a combined continuous illumination area of at least 120 degrees.

[0012] In an embodiment, the composite substrate comprises two layers of material. In an embodiment, the composite substrate is a flame retardant material and meets UL94V-0 requirements. For example, the composite substrate may be referred to as an FR-4 substrate.

[0013] In an embodiment, the housing comprises a two-part construction of a lens cover that fits over a front surface of the PCB where the first LED and the second LED areDocket No. 2024-1140 (S122995 1090WO)mounted, and a back cover that is positioned abutting a back surface of the PCB. The lens cover and the back cover can enclose the PCB board on all sides, while applying a flex force to the PCB that curves the PCB within the housing, to direct the LEDs at different angles and provide a wide illuminated area.

[0014] In an embodiment, the intermediate region comprises a first notch on a first edge and a second notch on a second edge. The lens cover comprises a first locating feature extending from a first wall of the lens cover where the first locating feature is at least partially received in the first notch, and a second locating feature extending from a second wall of the lens cover where the second locating feature is at least partially received in the second notch. The locating features align the PCB within the lens cover, and apply a holding force to hold the PCB in curved form within the lens cover, which improves ease of assembly - the back cover can be attached manually to the lens cover while the PCB is hold in the desired location within the lens cover, thereby controlling the forces applied to the PCB when the back cover is connected to and permanently affixed to the lens cover. The lens cover and back cover may be glued, welded, or otherwise joined together permanently and sealed.

[0015] In an embodiment, the back cover comprises a plurality of supporting ribs extending outward from a base layer of the back cover. The plurality of supporting ribs may include a first supporting rib with first flat surface that abuts against the first region of the PCB, and a second supporting rib with a second flat surface that abuts against the second region of the PCB. These ribs may apply a force to each of the flat regions of the PCB to keep them flat, while the ribs and lens cover are angled at other sections to apply the flexing force to the PCB.

[0016] In an embodiment, the lens cover and the back cover are joined with a sealed weld. For example, the lens cover and back cover may be joined with an ultrasonic weldDocket No. 2024-1140 (S122995 1090WO)that melts the lens cover and back cover to form a sealed weld. Additionally, or alternatively, the lens cover and back cover may be joined and sealed with an adhesive such as an epoxy or other suitable adhesive. Other materials or methods may be used to permanently j oin the lens cover and back cover in a sealed manner.

[0017] In an embodiment, a gap is located between a portion of the lens cover and the back cover, forming an opening through which a connector portion of the PCB occupies. The connector portion may comprise pads of the metal layer. A wire harness may be electrically coupled to the pads of the metal layer (e.g., through respective solder joints). The wire harness may comprise conductors (e.g., wires) that provide a signal and power to the LEDs, operative to turn the LEDs on (conducting) or off (non-conducting).

[0018] In an embodiment, the back cover comprises a strain relief rib extending from a base layer of the back cover at the opening. An adhesive is deposited in the opening, including being deposited between the connector portion and the strain relief rib. The adhesive seals the opening, and helps to provide strain relief to the connection between the PCB and wire harness.

[0019] In an embodiment, the back cover comprises a base layer with a first flat section, a second flat section, and a curved arc between the first flat section and the second flat section. The first flat section and second flat section may serve as flat pads for securely coupling the assembly to a power tool at opposite ends of the LED assembly.

[0020] In an embodiment, the lens cover comprises a curved front surface, a first side wall, and a second side wall. The first side wall and the second side wall may extend from opposing edges of the curved front surface. The ribs of the back cover and the PCB may be arranged between the side walls, to provide a snug fit for the PCB, maintain the curved shape of the PCB, and to form a hermetically sealed housing. The lens cover comprises a transparent material.Docket No. 2024-1140 (S122995 1090WO)

[0021] In an aspect, a power tool comprises a motor, driven by an electric power source, a tool housing, and an LED assembly. The LED assembly comprises an LED assembly¬ housing, and a printed circuit board (PCB) located within the LED assembly housing. The PCB includes a composite substrate comprising epoxy resin and glass fabric, a first LED mounted to a first region of the PCB, a second LED mounted to a second region of the PCB, and an intermediate region of the PCB, joining the first region and the second region. The first region and the second region have a flat configuration, and the intermediate region has a curved configuration. A metal layer is fixed to the PCB, the metal layer being electrically coupled to the first LED and to the second LED.

[0022] In an aspect, a family of power tools (e g., drills, saws, sanders, multi-tools, and / or grinders) is disclosed. Each of the power tools may comprise an LED assembly. The LED assembly comprises a housing, and a printed circuit board (PCB) located within the housing. The PCB includes a composite substrate comprising epoxy resin and glass fabric, a first LED mounted to a first region of the PCB, a second LED mounted to a second region of the PCB, and an intermediate region of the PCB, joining the first region and the second region. The first region and the second region are flat and the intermediate region is curved. A metal layer is fixed to the PCB, electrically coupled to the first LED and to the second LED. In this manner, the family may leverage a common LED assembly which can increase efficiency in manufacturing and assembly, while potentially improving reliability by channeling development efforts into less parts. In addition, different tools in the family may comprise different number of LED assemblies, which may be arranged on each tool to provide a wider or different area of illumination.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments, which,Docket No. 2024-1140 (S122995 1090WO)however, should not be taken to limit the embodiments described and illustrated herein, but are for explanation and understanding only.

[0024] FIG. 1 shows an isometric view of an LED assembly, in accordance with an exemplary embodiment of the disclosure.

[0025] FIG. 2A shows a bottom plan view of the curved PCB of the LED assembly of FIG. 1.

[0026] FIG. 2B shows a front elevation view of the curved PCB of FIG. 2A.

[0027] FIG. 3 A shows a schematic plan view of the PCB of the LED assembly of FIG. 1 in a flat configuration.

[0028] FIG. 3B shows a schematic side elevation view of the PCB of the LED assembly of FIG. 1 in a flat configuration.

[0029] FIG. 4 shows the PCB and electric harness thereof of the LED assembly of FIG.1, and an accompanying detail assembly view of selected components thereof.

[0030] FIG. 5 A shows a front isometric exploded view of the LED assembly of FIG. 1.

[0031] FIG. 5B shows a back isometric exploded view of the LED assembly of FIG. 1.

[0032] FIG. 6 shows an isometric view of the LED assembly of FIG. 1 and an accompanying detailed view of an opening of the LED assembly.

[0033] FIG. 7A shows a rear elevation view of selected components of the LED assembly of FIG. 1.

[0034] FIG. 7B shows a front elevation view of selected components of the LED assembly of FIG. 1.

[0035] FIG. 8 is an isometric view of a portion of a power tool including the LED assembly of FIG. 1. according to an exemplary embodiment of the disclosure.DETAILED DESCRIPTIONDocket No. 2024-1140 (S122995 1090WO)

[0036] In the following description, numerous details are set forth. It will be apparent, however, to one of ordinary7skill in the art having the benefit of this disclosure, that the embodiments described herein may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the embodiments described herein.

[0037] Insufficient visibility7or lighting when using power tools may lead to difficulties in operation and / or completing a project. Power tools may use PCB-mounted LEDs to illuminate a workpiece and area around the workpiece. Traditionally, PCBs are rigid and flat. LEDs may be mounted to these flat rigid PCBs, and the PCB may be mounted to a lens. Stiff PCBs may struggle to take a curved shape, and may crack upon being subject to one or more flexing force, or over time due to stress. In some cases, multiple separate PCBs with led diodes can be arranged at different areas of the curved lens. In such a case, however, the cost of this device may be driven higher due to increased number of parts and increased complexity in bringing wiring to the different PCBs. Some solutions may use a flexible PCB circuit, which, rather than being completely formed with a fiber-glass structure, utilizes a tape-like substrate such as a polyimide film (e.g., Kapton tape or similar film technology), to curve and bend as desired. Such an approach can further increase complexity7and cost as such films may be expensive. Further, such a design may be prone to failure due to transition points between different materials (e.g., a stiff PCB and the film), each having potentially different temperature expansion properties. Therefore, a curved LED assembly solution is desired using a single traditionally manufactured PCB material (e.g., fiberglass) that provides a wide area of luminance.

[0038] Aspects of the present disclosure relate to power tool having an LED assembly with a curved PCB that addresses deficiencies of traditional LED assemblies, such as but not limited to those discussed above. An LED assembly comprises a housing, and a PCBDocket No. 2024-1140 (S122995 1090WO)located within the housing. The PCB includes a composite substrate comprising epoxy resin and glass fabric, a first LED mounted to a first region of the PCB, a second LED mounted to a second region of the PCB, and an intermediate region of the PCB, joining the first region and the second region. The first region and the second region are arranged in a flat or planar configuration and the intermediate region is arranged in a curved configuration. A metal layer (e.g., an electric conducting layer) is fixed to the PCB, electrically coupled to the first LED and to the second LED. The housing may have a shape, size, and geometry that is complementary' to the PCB and that applies a flexing force to the PCB, causing the PCB to flex to its curved shape. The housing maintains the curved shape of the PCB as it resides within the housing.

[0039] The curved PCB may be sufficiently thin (e.g., less than about 1mm thick, less than about 0.5mm thick, having a thickness between about 0.3mm thick and about 0.5mm thick, e.g., about 0.4mm thick) to provide sufficient flexibility to allow for bent or curved arrangements. In an embodiment, the PCB circuit includes three planar or flat regions. Between each of these flat regions are curved regions. The flat regions and curved regions may alternate in sequence along the length of the PCB, (e.g., flat region, curved region, flat region, curved region, flat region, and so on). The number of flat regions and curved regions may vary to suit a particular application or a particular power tool.

[0040] Each of the flat regions may be filled with copper backplane that helps maintain the flat shape of that region, and also improves heat dissipation from the respective LED attached at that section. In contrast, each of the curved regions may comprise a sufficient amount of the metal conductor to carry electricity to and from each of the flat regions and the LEDs thereon, though additional conductive material could be provided without departing from the disclosure.Docket No. 2024-1140 (S122995 1090WO)

[0041] The housing may comprise a two-part construction, including a lens cover and a back cover that encloses the PCB and contributes to shaping the PCB into a curve. The lens cover may comprise a transparent material (e.g., a transparent polymer-based material).

[0042] The LED assembly may be mounted to a power tool, such as. for example, a reciprocating saw, an oscillating saw. a drill, a hammer drill, a circular saw, etc. In an example, a group of power tools may each have an LED assembly mounted thereon. The part count for this platform of tools may be reduced while reliability may be improved through concentration of design and testing efforts. The family of tools may each comprise the same LED assembly in either the same exact configuration, or with varying numbers of LEDs, flat regions, and curved regions.

[0043] FIG. 1 shows an isometric view of an LED assembly 102, in accordance with an exemplary embodiment of the disclosure. Features described and shown with respect to FIG. 1 may extend to or correspond to other embodiments described with respect to other figures.

[0044] LED assembly 102 includes an LED assembly housing 114 that houses a printed circuit board (PCB) 104. PCB 104 is located inside of LED assembly housing 114 and may be fully enclosed by the LED assembly housing 114.

[0045] The PCB 104 may comprise a substrate formed of a composite material such as, for example, an epoxy resin and glass fabric. In some embodiments, the substrate 105 may be referred to as fiber glass. The PCB 104 may have a plurality of flat regions joined by one or more curved regions. LEDs such as surface mount devices (SMDs) and / or other electronics may be soldered to the flat regions of the PCB 104, such as on conductive pads of a metal layer that is deposited onto PCB 104. In an embodiment, each of the curvedDocket No. 2024-1140 (S122995 1090WO)regions may be component-less, which may promote flexibility, as described further herein.

[0046] In the illustrated embodiment, the PCB 104 comprises three flat regions, such as, for example, a first region 106, a second region 110, and a third region 122. The first region 106, second region 110, and third region 122 can be flat regions along which the substrate 105 of the PCB 104 is arranged in a generally planar configuration.

[0047] Between each of these flat regions 106, 110, 122, are curved regions such as an intermediate region 124 between the regions 106, 110 and an intermediate region 108 between the regions 110, 122. The flat regions and curved regions may alternate in sequence along the length of the PCB, (e.g., flat region, curved region, flat region, curved region, flat region, and so on). The number of flat regions and curved regions may vary to suit a particular application or a particular power tool.

[0048] The PCB 104 may include a first LED 118 that is mounted to the first region 106 of the PCB 104, a second LED 120 that is mounted to a second region 110 of the PCB 104, and a third LED 130 mounted to the third region 122 of the PCB 104.

[0049] An intermediate region 108 of the PCB 104 joins the first region 106 and the second region 110. The first region 106 and the second region 110 are flat in configuration, for example, so as to form a planar surface of the PCB 104 at these regions that is straight and free from curvature.

[0050] The intermediate regions 108, 124 are at least partially curved in configuration, for example, such that the substrate 105 of the PCB 104 in the intermediate regions 108, 124 are at least partially curved.

[0051] The housing 114 of the LED assembly 102 may also be at least partially curved, and an interior portion of the LED assembly housing 114 can hold the PCB 104 in an at least partially curved configuration such that the LEDs 118. 120, 130 mounted along theDocket No. 2024-1140 (S122995 1090WO)PCB 104 each have a different direction of illumination (e.g., scoping outward) to provide a widened illumination area. The LEDs 118, 120, 130 are thus oriented to project light along different directions due to the different orientations of the regions 118, 120, 130.

[0052] The PCB 104 may comprise a metal layer, fixed to the substrate 105 PCB. The metal layer can comprise a suitable conductive material such as, for example, copper, copper alloy, or other suitably conductive metal. The metal layer can comprise multiple metal layers, each bonded to a layer of the composite substrate (e.g.. through an etching and / or laminating process), and the metal layers may be electrically connected to each other through vias (e.g., paths) from one layer of the substrate to another layer of the substrate. The metal layer may comprise traces and / or backplanes that are electrically coupled to the LEDs 118, 120, 130 mounted on PCB 104.

[0053] In an embodiment, each of the flat regions (e.g., first region 106, second region 110, third region 122) may be filled with copper backplane that helps maintain the flat shape of that region, and also improves heat dissipation from the respective LED attached at that section. In an example, the area of each flat region may be at least 60% occupied with the metal layer. In an example, the area of each flat region may be at least 80% occupied with the metal layer. In an example, the area of each flat region may be at least 95% occupied with the metal layer. In contrast, each of the curved regions (e.g., intermediate region 124, intermediate region 108) may comprise a sufficient amount of the metal conductor to carry electricity' to and from each of the flat regions and the LEDs thereon, though additional conductive material could be provided without departing from the disclosure.

[0054] In an embodiment, the LED assembly housing 114 may comprise a lens cover 112 and a back cover 116. The lens cover 112 may comprise a transparent material (e.g., a transparent polymer-based material). The PCB 104 may be pressed into a curved spaceDocket No. 2024-1140 (S122995 1090WO)formed by the shape of the interior walls of the lens cover 112. The shape boundaries of the interior walls of the lens cover 112 are shown with solid black lines, while the exterior lines of the lens cover 112 are shown with faint fill.

[0055] The fit of the PCB 104 within the lens cover 112 may cause the PCB 104 to curve at the one or more intermediate regions (e.g., 124, 108) and remain flat at the two or more flat regions, e.g., regions 106, 110, 122. Once the PCB 104 is fit into the lens cover 112, the back cover 116 may abut against the PCB 104 from a back side of the PCB 104, opposite of the LEDs 118, 120. The pressure from the back cover 116 may further apply force to the PCB 104 to form and maintain the PCB 104 into a desired curved configuration. This curved shape may be at least partially defined by the geometry' of the interior space between the lens cover 112 and the back cover 116 in the LED assembly housing 114.

[0056] In an embodiment, the lens cover 112 and the back cover 116 may be mechanically joined together and sealed. In an embodiment, the lens cover 112 and back cover 116 may be joined into a single monolithic body, for example, through an ultrasonic weld that melts and fuses the lens cover 112 to the back cover 116.

[0057] The LED assembly housing 114 may comprise an opening 128 on a side of the LED assembly 102. This opening serves as a point of entry for electrical wiring to and from the PCB 104. The electrical wiring 126 may comprise wires joined together as a wire harness (such as wire harness 402 seen in Fig. 4) and connected to solder pads on the PCB 104. These solder pads are part of the overall metal layer deposited on the PCB 104, and may be located at the point of entry at the opening 128.

[0058] Once the lens cover 112 and back cover 116 are joined, the top opening 128 may be filled with a sealant such as, for example, a clear silicone adhesive (e.g., a roomDocket No. 2024-1140 (S122995 1090WO)temperature vulcanizing (RTV) silicone) or other adhesive. However, the interior of the housing 114 may be devoid of a sealant without departing from the disclosure.

[0059] The LED assembly 102 may be mounted to a power tool, such as, for example, a handheld power tool, as described further herein. A power tool may include a tool head that interacts with a working object. For example, the LED assembly 102 may be fixed to a multi-tool power tool, with an oscillating tool head that, depending on the attachment, can cut, sand, grind, etc. The power tool may be held at different angles to approach and operate on a work piece from different angles. It is beneficial and desirable to illuminate multiple directions around the tool head, to give a wide angle of visibility (e.g., a cone of illuminated visibility) around the tool head.

[0060] In an embodiment, a family of tools may each comprise LED assembly 102, in either the same or a similar configuration, or with varying numbers of LEDs, flat regions and curved regions.

[0061] FIG. 2A shows a plan view of the curved PCB 104 of the LED assembly 102 of FIG. 1. FIG. 2B shows a front elevation view of the curved PCB 104 of FIG. 2A. Features described and shown with respect to FIG. 2A and FIG. 2B may extend to or correspond to other embodiments described with respect to other figures.

[0062] As shown, the first intermediate region 108 and second intermediate region 124 are at least partially curved so that the surfaces of each flat region 106, 110, 122 face different directions. In this regard, the surface mount LEDs 118, 120, and 130 can be orientated on the respective flat regions 106, 110, 122 to project light along different directions of illumination, such as respective directions of illumination DI, D2, D3. In the illustrated embodiment, the direction of illumination D2 associated with the LED 118 mounted along the flat region 106 can be a generally straight direction relative to which the direction of illumination DI associated with the LED 130 mounted along the flat regionDocket No. 2024-1140 (S122995 1090WO)122 and the direction of illumination D3 associated with the LED 120 mounted along the flat region 110 are obliquely arranged.

[0063] Although shown with three flat regions and two curved regions, it should be understood that a PCB 104 and the PCB assembly LED assembly 102 can have a different number and / or arrangement of flat regions and / or intermediate regions without departing from the scope of the present disclosure. Further, the number of LEDs may differ from the number of flat regions. For example, PCB 104 is shown with three flat regions with three LEDs, but in an embodiment, PCB 104 may comprise only 1 LEDs in any one of the three flat regions, and in another embodiment. PCB 104 may comprise only 2 LEDs in any combination of the three flat regions.

[0064] FIG. 3 A shows a schematic plan view of the PCB 104 of the LED assembly 102 of FIG. 1 in a flat configuration. FIG. 3B shows a schematic side elevation view of the PCB 104 of the LED assembly 102 of FIG. 1 in a flat configuration. Features described and shown with respect to FIG. 3A and FIG. 3B may extend to or correspond to other embodiments described with respect to other figures.

[0065] The configuration of the PCB 104 in the flat or planar configuration shown promotes at least partial curvature at the intermediate regions 108, 124 between the flat regions 122, 106, 110 when received in the housing 114 as described herein.

[0066] PCB 104 may comprise an overall length L. In an embodiment, the length L has a range of about 30mm to about 80mm, for example, from about 40mm to about 60mm. In an embodiment, the length L has a range of about 50mm to about 52mm.

[0067] In an embodiment, each of the flat regions 106, 110, 122 may comprise a width W2. Each of the intermediate regions 108, 124 may comprise a width W3. The width may¬ be perpendicular to the length L, at which the flat regions 106, 110, 122 and intermediate regions 108, 124 alternate in sequence. The width W2 of each flat region 106, 110, 122Docket No. 2024-1140 (S122995 1090WO)may be greater than a width W3 of each intermediate region 108, 124, thereby helping the respective intermediate region 108, 124 to flex while helping the respective region 106, 110, 122 to stay flat.

[0068] In an embodiment, width W2 ranges from about 6mm to about 10mm, for example, from about 7 mm to about 9 mm. In an embodiment, the width W2 may be about 8mm. In an embodiment, the width W3 ranges from about 3.5mm to about 7mm, for example, from about 4mm to about 6mm. In an embodiment, the width W3 is about 5mm.

[0069] In an embodiment, a thickness T of the substrate 105 of the PCB 104 is uniform (e.g., the same) throughout the PCB 104. In an embodiment, the thickness has a range of about 0.25mm to about 0.60mm, for example, about 0.35mm to about 0.50mm. In an embodiment, the thickness is about 0.40mm.

[0070] In an embodiment, a length LI of an intermediate region 108, 124 ranges from about 7mm to about 11mm, for example, from about 8mm to about 10mm or from about 9.2mm to about 9.6mm.

[0071] In an embodiment, a ratio of the length LI of a respective intermediate region 108, 124 to the thickness T of the substrate 105 of the PCB 104 is at least about 15:1, or at least about 20:1, or at least about 23:1. The thickness of the substrate 105 of the PCB 104 and above ratios may promote a controlled bending of the intermediate region to take its curved shape.

[0072] In an embodiment, one or more of the intermediate regions 108, 124 of the PCB 104 are notched. For example, a respective intermediate region 108, 124 of the PCB 104 may comprise first notch 316 on a first edge and a second notch 308 on a second edge thereof. The notches 308 and 316 may be aligned with each other in the opposite edges of the respective intermediate region 108, 124, as shown. The notches may reduce the widthDocket No. 2024-1140 (S122995 1090WO)W3 of the intermediate regions to a width W4. In an embodiment, the width W3 ranges from about 3mm to about 6.5mm, for example from about 4mm to about 5mm.

[0073] In some embodiments, a metal layer is deposited one or more of the respective flat regions 106. 110, 122 of the PCB 104. In addition to the required traces to control the LEDs, each of the flat regions 106. 110. 122 may comprise a solid unbroken, e.g., continuous, metal plane. In an embodiment, each plane may occupy at least about 60% of the respective flat region 106, 110, 122. In an embodiment, each plane may occupy at least about 70% of the respective flat region 106. 110, 122. In an embodiment, each plane may occupy at least about 85% of the respective flat region 106, 110, 122. In an embodiment, each plane may occupy at least 95% of the respective flat region 106, 110, 122. Each plane may serve as a stiffening support that helps to hold the respective flat region f06, 110, f22 in a flat state, for example, even under an applied flexing force or a biasing force that tends to return the substrate 105 of the PCB 104 to a flat condition.

[0074] In some embodiments, the intermediate regions 124, 108 are free from said metal planes - the metal layer that is deposited in each of the one or more intermediate regions may be thin traces of metal which may occupy about 5% or less of the area in the respective intermediate region 108, 124. This reduces the amount of metal in the respective intermediate region 108, 124 to promote curvature of the respective intermediate region 108, 124 to take the curved shape when placed in the housing 114.

[0075] In an embodiment, PCB 104 may comprise multiple composite substrate layers. In an embodiment, PCB 104 may comprise two layers of the composite substrate 105, a first layer 312 and a second layer 310. A metal layer 314 may be etched onto the first layer 312, and / or the second layer 310. One or both of the layers 312, 310 of the composite substrate may comprise fiberglass. In an embodiment, the composite substrate materialDocket No. 2024-1140 (S122995 1090WO)may be an FR-5 substrate that is formed of a fiber glass reinforced polyimide, having a configuration that is flame retardant and that meets UL94V-0 requirements.

[0076] FIG. 4 shows the PCB 104 with an electric harness 402 thereof, and an accompanying detail assembly view of selected components thereof. Features described and shown with respect to FIG. 4 may extend to or correspond to other embodiments described with respect to other figures.

[0077] The wire harness 402 may comprise an electric connector housing 404 and wires 410. Wires 410 may be wrapped in a shrink wrap 408 sheath. The wires 410 may be connected to solder pads on the PCB 104 of an LED assembly such as LED assembly 102. Wires 410 may be electrically coupled to pins or sockets of connector housing 404.

[0078] In an embodiment, the wire harness 402 may comprise an inline connector 406 which may be wrapped in an insulated sheath (e.g., shrink wrap). In an embodiment, the wires 410 are soldered to pads of PCB 104 through a solder joint (e.g., a lap joint or other suitable solder joint). In an embodiment, the resistor 406 may be omitted or placed outside of the harness on a mating circuit (e.g., a switch circuit) that is not shown.

[0079] FIG. 5 A shows a front isometric exploded view of the LED assembly 102 of FIG.1. FIG. 5B shows a back isometric exploded view of the LED assembly 102 of FIG. 1. Features described and shown with respect to FIG. 5A and FIG. 5B may extend to or correspond to other embodiments described with respect to other figures. Some of the parts have been rearranged so that features may be made visible for the figure.

[0080] LED assembly 102 includes an LED assembly housing, formed from a back cover 116 and a lens cover 112, and a PCB 104, located within the LED assembly housing. The PCB 104 has a fiberglass substrate, respective flat regions and intermediate regions, as described in other sections. The housing may be configured with a geometry that applies a flexing force to the PCB, causing the PCB to flex and maintain the curved shape.Docket No. 2024-1140 (S122995 1090WO)

[0081] The lens cover 112 fits over a front surface of the PCB 104, covering the LEDs that are mounted on the PCB. The back cover 116 abuts the back surface of the PCB 104. The PCB 104 bends and conforms to the internal space between the lens cover 112 and back cover 116, to give the PCB 104 its at least partially curved shape.

[0082] As described herein, a respective intermediate region 108, 124 of the PCB 104 may comprise the first notch 316 on a first edge and a second notch 308 on a second edge thereof. Within the lens cover 112, the lens cover 112 may comprise a plurality of first locating features 514 extending from a first or upper wall 528 of the lens cover, and a plurality of second locating features 512 extending from a second or lower wall 530 of the lens cover 112. The first locating feature 514 may be complementary in shape and size to the first notch 316, and the second locating feature 512 may be complementary in shape and size to the second notch 308, so that they each are at least partially received or fitted in the notches respectively. In an embodiment, each one of the intermediate regions may¬ be notched, where corresponding locating features are at least partially received into each notch when the PCB 104 rests within the housing.

[0083] The locating features (e.g., beams, tabs, other protrusions, etc.) help maintain the desired curvature, alignment, and location of the PCB 104 within the housing 114, minimizing, inhibiting, preventing, and / or otherwise avoiding movement of the PCB 104 relative to the housing 114 due to vibration and external forces, while also providing a convenient guiding structure for proper alignment and placement of the PCB 104 within the housing 114 of the LED assembly 102.

[0084] For example, upon assembly, the PCB 104 can be pressed into the inside of the lens cover 112, where the locating features 512, 514 will be at least partially received within the respective notches 316, 308 of the PCB 104 to position and hold the PCB 104Docket No. 2024-1140 (S122995 1090WO)in place. This may facilitate enclosure of the PCB 104 within the space formed between the lens cover 112 and the back cover 116.

[0085] In an embodiment, the back cover 116 comprises a plurality of supporting ribs 502, 508, 504, 510, 506. The supporting ribs 502, 508, 504, 510, 506 may extend outwardly from a back layer or backplate 524 of the back cover 116. In some embodiments, the backplate 524 of the back cover 116 can be at least partially curved in configuration.

[0086] Each of the flat regions 106, 110, 122 of the PCB 104 may abut against a flat surface of a supporting rib 502, 508, 504, 510, 506. In an embodiment, each of the intermediate regions 1 8, 124 of the PCB 104 may also abut against a supporting rib. In an embodiment, supporting ribs 508, 510 may have a shorter length relative to the intermediate regions 108. 122 than the other supporting ribs 502, 504, 506 relative to the flat regions 106, 110. 122. The supporting ribs 502, 504, and 506 may have flat surfaces that abut against the flat regions 106. 110. 122 to help hold those regions in a flat and planar configuration, while the supporting ribs 508, 510 applies a force in a middle of each intermediate region 108, 122 to help them bend and curve. In an embodiment, the supporting ribs 508. 510, the notches 308. 316, and the locating features 512. 514 may be located proximate a middle of the respective intermediate region 108, 122. thereby helping to curve each intermediate region 108. 122 with reduced stress to the PCB 104.

[0087] In an embodiment, the lens cover 112 and the back cover 116 are joined with a sealed weld. In an embodiment, they are sealed with an ultrasonic weld. Ultrasonic welding may melt a portion of the lens cover 112 to permanently join it to back cover 116. In an embodiment, the lens cover 112 may comprise an edge 526 that contacts a corresponding surface of the back cover 116. The edge 526 may have a complementary profile to the back cover 116. In an embodiment, the back cover 116 may comprise a baseDocket No. 2024-1140 (S122995 1090WO)layer 524 that has flat sections 520 and 522, and a curved section 538 extending therebetween. Flat sections 520 and 522 may be at opposite ends of the back cover 116. The curved section 538 may be located directly between the flat section 520 and flat section 522. The edge 526 may fit against the surface of the base layer 524 and be welded together, except for at opening 128. In some embodiments, the opening 128 may be formed from by a gap between the lens cover 112 and back cover 116.

[0088] In an embodiment, the back cover 116 comprises a strain relief rib 532 having a surface that extends from a base layer 524 of the back cover 116 at the opening 128. The PCB 104 may comprise a connector portion 534 that extends from one of the PCB regions such as, for example, from one of the flat sections. An adhesive may be deposited in the opening 128, including between the connector portion 534 of the PCB 104 and the strain relief rib 532, in order to seal the opening 128.

[0089] In an embodiment, the lens cover 112 comprises a curved front surface 536. The curved front surface 536 may be located between the first side wall 528 and the second side wall 530 of the lens cover 112. The first side wall 528 and the second side wall 530 extend from opposing edges of the curved front surface 536.

[0090] FIG. 6 shows an isometric view of the LED assembly 102 of FIG. 1 and an accompanying detailed view of an opening associated with the LED assembly 102. Features described and shown with respect to FIG. 6 may extend to or correspond to other embodiments described with respect to other figures.

[0091] As shown, the lens cover 112 of the housing 114 of the LED assembly 102 may include a cut out portion 604, which may, in an embodiment, be a U-shaped opening having 3 walls as shown. A gap 602 is formed as space between the cut out portion 604 of the lens cover 112 and the back cover 116, forming an opening 128 through which the connector portion 534 of the PCB 104 extends.Docket No. 2024-1140 (S122995 1090WO)

[0092] The connector portion 534 comprises pads of the metal layer that the wire harness 402 may be connected to, for example, through one or more solder joints). The strain relief rib 532 of the back cover 116 may extend partially into the gap 602 formed by the cut out portion 604 of the lens cover 112. The strain relief rib 532 may be thus positioned to facilitate alignment of the back cover 116 and the lens cover 112 when mated together for welding. When a sealant (e.g., an adhesive or epoxy) is deposited in the opening 128, the sealant seals the opening 128, thereby protecting the PCB 104 from outside elements, e.g., debris, moisture, etc. The wire harness 402 may be electrically and physically coupled to the connector portion 534, such as through one or more solder joints that fix wires of the wire harness 402 to the metal layer of PCB 104. Further, the combination of sealant with the strain relief rib 532 may provide strain relief to the connector portion 534 of the PCB 104 and to the solder joint connecting to the wire harness 402.

[0093] FIG. 7A shows a rear elevation view of selected components of the LED assembly 102 of FIG. 1. FIG. 7B shows a front elevation view of selected components of the LED assembly 102 of FIG. 1. Features described and shown with respect to FIG. 7A and FIG.7B may extend to or correspond to other embodiments described with respect to other figures.

[0094] The connector portion 534 of the PCB 104 extends out of the opening 128 of the LED assembly housing 114. This connector portion 534 may comprise pads 702 of a metal layer that is deposited on and fixed to the PCB 104. A surface mount connector (e.g., with pins or a socket), may be soldered to these pads. In another example, wires of a wire harness 402 may directly be soldered to the pads (e.g., with a lap joint or other suitable soldered joint).

[0095] FIG. 8 is an isometric view of a portion of a power tool including the LED assembly 102 of FIG. 1, according to an exemplary embodiment of the disclosure.Docket No. 2024-1140 (S122995 1090WO)

[0096] The power tool 802 may comprise an electric motor that may be operative to spin, oscillate, reciprocate, or vibrate a tool head (e.g., a drill bit, a sanding disc, a saw blade, or other tool head). Power tool 802 may comprise the LED assembly 102, which may comprise a plurality of LEDs such as, for example, LED 118, LED 120, and LED 130. Each of the LEDs may be mounted onto the PCB 104 to direct light in a different direction. In an embodiment, the illuminated area of the LEDs may be a cone that covers at least about 90 degrees forwardly of the power tool 802. In an embodiment, the illuminated area covers at least about 100 degrees, or at least about 110 degrees. In an embodiment, the illuminated area covers about 120 degrees.

[0097] The power tool 802 may comprise a power tool housing 804 that holds the LED assembly 804. In an embodiment, one or more portions 806, 808 of the power tool housing 804 may be placed over respective portions of the LED assembly 102, as shown. These portions may help hold and fix the LED assembly 102 to the power tool housing 804 and remaining parts of the power tool 802. Furthermore, such an arrangement can selectively expose respective portions of the LED assembly 102, for example, such portions proximate the LEDs 118, 120, 130.

[0098] In an embodiment, a plurality of power tools 802, each having a different form and / or function (e.g., a circular saw, a multi -tool, a drill, a hammer drill, a reciprocating saw, an oscillating tool, etc.) may comprise LED assembly 102. In an embodiment, a power tool 802 may comprise multiple LED assemblies 102, which may be arranged on the power tool in radial succession, to provide an increased cone of illumination (e.g., about 240 degrees, about 360 degrees). It will be understood that configurations of the power tool 802 relating to motors, motor controls, tool heads, power supplies such as batteries, etc., may vary depending on application.Docket No. 2024-1140 (S122995 1090WO)

[0099] It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. The scope should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0100] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments w ere chosen and described in order to best explain the principles and practical applications of the various embodiments, to thereby enable others skilled in the art to best utilize the various embodiments with various modifications as may be suited to the particular use contemplated.

Claims

Docket No. 2024-1140 (S122995 1090WO)CLAIMSWhat is claimed is:

1. A power tool, comprising:a tool housing;a light emitting diode (LED) assembly at least partially received in an interior of the tool housing, the LED assembly comprising:an LED assembly housing; anda printed circuit board (PCB) located within an interior of the LED assembly housing, the PCB comprising:a composite substrate comprising epoxy resin and glass fabric;a first LED mounted to a first region of the composite substrate;a second LED mounted to a second region of the composite substrate;an intermediate region of the composite substrate joining the first region and the second region, wherein the first region and the second region are arranged in a flat configuration and the intermediate region is arranged in a curved configuration relative to the first region and the second region; anda metal layer fixed to the PCB, the metal layer electrically coupled to the first LED and to the second LED.

2. The power tool of claim 1. wherein the intermediate region comprises a width that is less than a width of the first region and of the second region.

3. The power tool of claim 1 , wherein a ratio of a length of the intermediate region to a thickness of the PCB is at least about 15:1.Docket No. 2024-1140 (S122995 1090WO) 4. The power tool of claim 1, wherein a thickness of the PCB is less than or equal to about 0.6 mm.

5. The power tool of claim 1. wherein the metal layer that is deposited in the first region and in the second region occupies at least about 60% of the first region and the second region.

6. The power tool of claim 1, wherein the PCB further comprisesa third LED mounted to a third region of the PCB; anda second intermediate region located between the first region of the PCB and the second region of the PCB, wherein the third region of the PCB is flat and the second intermediate region is curved.

7. The power tool of claim 1, wherein an illumination area of the LED assembly comprises at least about 120 degrees of coverage.

8. The power tool of claim 1, wherein the composite substrate comprises two layers of material.

9. The power tool of claim 1, wherein the composite substrate is comprised of a flame retardant material that meets UL94V-0 requirements.

10. The power tool of claim 1, wherein the housing comprisesa lens cover that fits over a front surface of the PCB on which the first LED and the second LED are mounted; anda back cover positioned abutting a back surface of the PCB.

11. The power tool of claim 10, wherein the intermediate region comprises a first notch on a first edge and a second notch on a second edge, and wherein the lens coverDocket No. 2024-1140 (S122995 1090WO)comprises a first locating feature extending from a first wall of the lens cover and at least partially received in the first notch, and a second locating feature extending from a second wall of the lens cover and at least partially received in the second notch.

12. The power tool of claim 10, wherein the back cover comprises a plurality of supporting ribs extending outward from a base layer of the back cover, the plurality of supporting ribs comprising a first supporting rib with a first flat surface abutting the first region of the PCB and a second supporting rib with a second flat surface abutting the second region of the PCB.

13. The power tool of claim 10, wherein the lens cover and the back cover are joined with a sealed weld.

14. The power tool of claim 10, wherein a gap is formed between a portion of the lens cover and a portion of the back cover, the gap forming an opening through which a connector portion of the PCB extends, and wherein the connector portion comprises portions of the metal layer to which a wire harness is connected.

15. The power tool of claim 14, wherein the back cover comprises a strain relief rib extending from a base layer of the back cover at the opening, and an adhesive is deposited in the opening including between the connector portion and the strain relief rib.

16. The power tool of claim 10, wherein the back cover comprises a base layer with a first flat section, a second flat section, and a curved arc between the first flat section and the second flat section.Docket No. 2024-1140 (S122995 1090WO)17. The power tool of claim 10, wherein the lens cover comprises a curved front surface, a first side wall, and a second side wall, wherein the first side wall and the second side wall extend from opposing edges of the curved front surface.

18. The power tool of claim 10, wherein the lens cover comprises an at least partially translucent material.

19. The power tool of claim 1, wherein the lens cover is at least partially exposed along the tool housing.

20. A system comprising a plurality of separate handheld power tools, each of the separate handheld power tools comprising:a tool housing;a light emitting diode (LED) assembly at least partially received in an interior of the tool housing, the LED assembly comprising:an LED assembly housing; anda printed circuit board (PCB) located within an interior of the LED assembly housing, the PCB comprising:a composite substrate comprising epoxy resin and glass fabric;a first LED mounted to a first region of the composite substrate;a second LED mounted to a second region of the composite substrate;an intermediate region of the composite substrate joining the first region and the second region, wherein the first region and the second region are arranged in a flat configuration and the intermediate region is arranged in a curved configuration relative to the first region and the second region; anda metal layer fixed to the PCB, the metal layer electrically coupled to the first LED and to the second LED.

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