Console Display Assembly With PCB Light Reflecting Cups
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Solution Overview
Problem
Existing alphanumeric display assemblies in home appliances face challenges in achieving bright and cost-effective illumination, often relying on costly encapsulation methods that result in less appealing and less bright displays over time.
Innovation Solution
The use of a printed circuit board (PCB) with holes and light emitting diodes (LEDs) combined with a light reflector assembly, where light reflecting cups are strategically positioned to reflect LED light through holes in the PCB, providing a bright and efficient illumination solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If encapsulation methods are used to illuminate display elements, then the display elements are protected, but the manufacturing cost increases and the display brightness decreases over time
Solution Approach 1:
The patent removes the encapsulation material from the display assembly, extracting only the essential illumination function. The display elements are mounted directly to the PCB without encapsulation, and LEDs are used to provide protection and illumination without requiring costly encapsulation materials or processes.
Solution Approach 2:
The patent employs inexpensive LED components that can be easily replaced if needed, rather than using expensive encapsulation materials. The LEDs serve both as protective covers and as illumination sources, providing a cost-effective solution that maintains display brightness over time.
2Reliability
If encapsulation methods are used to illuminate display elements, then the display elements are protected, but the display brightness becomes less appealing over time
Solution Approach 1:
The patent removes encapsulation material that would diminish display brightness over time. By eliminating the encapsulation layer, the display elements remain consistently bright and appealing throughout their operational life.
Solution Approach 2:
The patent introduces LEDs as intermediary elements that provide both protection and illumination. The LEDs are positioned to illuminate the display elements from behind, ensuring consistent brightness without the degrading effects of encapsulation materials.
3Device complexity
If LEDs are mounted adjacent to holes in the PCB, then the structure is simplified, but the light distribution may be uneven
Solution Approach 1:
The patent positions LEDs in a different spatial dimension relative to the display elements. The LEDs are mounted on the rear side of the PCB adjacent to holes, illuminating the display elements from behind through the holes. This rear-illumination approach simplifies the structure while achieving uniform light distribution across the display.
Solution Approach 2:
The patent uses the holes in the PCB as optical pathways, copying the light distribution pattern needed for uniform illumination. The holes are positioned and sized to replicate the desired light distribution across the display elements, achieving uniformity without complex LED mounting structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration achieves a desirably bright output light intensity while being cost-efficient, reducing the need for expensive encapsulation methods and maintaining display brightness over time.
Implementation Method 1
a plurality of light emitting diodes (LEDs) mounted to the rear side, wherein one LED is mounted adjacent to each hole
Implementation Method 2
a plurality of light reflecting cups arranged therein so that each light reflecting cup covers the one LED and the adjacent hole, and is spaced from the one LED and the adjacent hole to reflect light from the LEDs through the holes
Data Source
AI summary
In one aspect, a device has a controller and a fascia assembly, with a fascia, and a printed circuit board (PCB) mounted to the fascia. The PCB has a plurality of holes, and a plurality of light emitting diodes (LEDs), wherein one LED is mounted adjacent to each hole. The device also includes a wiring harness coupling the controller to the PCB wherein the LEDs may be energized according to signals received from the controller; and a console adjacent the PCB. The console has a plurality of light reflecting cups arranged therein so that each light reflecting cup covers an LED and the adjacent hole to reflect light from the LEDs through the holes so that the light is visible through the fascia assembly.