Electronic Cover with Conductive Ink Tracks
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Solution Overview
Problem
Existing electric lighting devices have cumbersome assembly processes due to multiple sub-assemblies from different suppliers, with design constraints and complex administration, particularly with the mounting of LED boards, lenses, test buttons, and indicator LEDs on plastic covers.
Innovation Solution
An electronic cover with integrated conducting electrical track structures, printed using conductive ink onto or into a 3D printed plastic material, allowing for direct mounting of LEDs and buttons, and connection to a main PCB via a connector, effectively functioning as a PCB within the cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sub-assemblies from different suppliers are used, then functional requirements can be met, but assembly process becomes cumbersome and complex
Solution Approach 1:
The patent merges the cover and PCB into a single integrated component. The cover is manufactured with embedded conducting track structures that directly connect to LED boards, lenses, buttons, and indicator LEDs, eliminating the need for separate PCB assembly and reducing multiple connection points to a single unified structure.
Solution Approach 2:
The integrated cover serves multiple functions simultaneously: it provides structural housing, electrical conduction through embedded tracks, mechanical mounting for LED boards and lenses, and electrical connection for buttons and indicator LEDs. This multi-functional design replaces multiple specialized components with one universal element.
2Adaptability or versatility
If multiple separate components are mounted on the cover, then functional requirements are satisfied, but design flexibility is constrained by component shapes
Solution Approach 1:
By combining the cover and PCB into one integrated component with embedded conducting tracks, the design is freed from the constraint of fitting separate PCB components into the cover. The conducting tracks are embedded directly into the cover material, allowing freeform 3D shapes without compromising electrical connectivity.
3Adaptability or versatility
If multiple sub-assemblies are used, then functional requirements can be met, but administration and coordination become complex
Solution Approach 1:
The patent consolidates multiple sub-assemblies (cover, PCB, LED board mounting structures, button mounting structures) into a single manufactured component. This reduces the number of parts that need to be ordered, tracked, and coordinated from multiple suppliers to one integrated component.
4Ease of manufacture
If traditional separate PCB and cover assembly is used, then manufacturing is straightforward for each component, but overall manufacturing process becomes cumbersome
Solution Approach 1:
The conducting track structures are embedded into the cover during the cover manufacturing process itself, before the cover is assembled with other components. This preliminary integration of electrical connectivity into the cover structure eliminates subsequent assembly steps for connecting PCB and cover.
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 solution simplifies the assembly process, reduces failure rates from multiple connections, enhances design flexibility, and streamlines the supply chain by integrating multiple functions into a single component, while maintaining aesthetic freedom.
Implementation Method 1
printed using conductive ink onto or into a 3D printed plastic material
Data Source
AI summary
An electronic cover for an electrical lighting device includes a conducting electrical track structure for lighting components and control components.