Tool Illumination Source With Fastener-Free LED Mounting
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Solution Overview
Problem
Existing hand tools, such as motorized ratchet wrenches, struggle with inadequate illumination in dimly lit and restricted spaces due to single LEDs that only illuminate a small area, and additional LEDs require bulky structures and fasteners, making them difficult to use.
Innovation Solution
An illumination source with LEDs disposed on a circuit board shaped to fit the tool housing, retained without fasteners, using a circumferential rim and lens to direct light away from the user's eyes and enhance surrounding illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple LEDs are added to illuminate a larger area, then illumination coverage is improved, but device complexity and bulk increase due to additional structures and fasteners
Solution Approach 1:
The illumination source is segmented into multiple individual LEDs mounted on a circuit board, allowing each LED to contribute to overall illumination coverage while the circuit board provides an integrated mounting structure that eliminates the need for separate fasteners and mounting structures for each LED
Solution Approach 2:
Multiple LEDs are merged onto a single circuit board that is shaped to correspond with the internal geometry of the tool housing, creating an integrated illumination assembly that fits within the existing housing contours without requiring additional external structures or fasteners
2Illumination intensity
If additional structures and fasteners are added to mount multiple LEDs, then illumination coverage is improved, but the tool becomes bulky and harder to use in restricted spaces
Solution Approach 1:
The circuit board with multiple LEDs is nested within the existing tool housing by shaping the circuit board to substantially correspond with the internal geometry of the housing, allowing the illumination source to be contained within the existing volume without protruding or requiring additional mounting structures
Solution Approach 2:
A flexible circuit board is used to mount the LEDs, allowing the illumination source to conform to the internal geometry of the housing and be retained without fasteners, thereby maintaining a compact tool size suitable for restricted spaces
3Device complexity
If a single LED is used to minimize complexity, then device complexity is reduced, but illumination coverage remains insufficient for dimly lit areas
Solution Approach 1:
The single LED is segmented into multiple individual LEDs mounted on a circuit board, with each LED contributing to the overall illumination coverage, while the circuit board provides an integrated mounting structure that maintains relative simplicity
Solution Approach 2:
The circuit board serves multiple functions: it provides electrical connections for multiple LEDs, structurally supports the LEDs, and acts as a mounting component that is shaped to correspond with the housing internal geometry, eliminating the need for separate 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
The solution provides improved, compact illumination by directing light towards the work area, reducing glare and enhancing visibility without adding bulk, thus improving usability in confined spaces.
Implementation Method 1
a lens adapted to diffuse light emitted by the illumination elements
Implementation Method 2
The lens and the rim are cooperatively adapted to direct light emitting from the illumination elements away from a user's eyes and towards a work area of the tool
Data Source
AI summary
An illumination source disposed in a housing of a tool without the need for fasteners or snaps. The illumination source includes a number illumination elements, such as LEDs, disposed on a circuit board. A lens and the housing cooperatively direct light emitted by the illumination elements away from a user's eyes during use of the tool.