Flexible Light Pipe with Press-Fit Adapter for PCB Mounting
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Solution Overview
Problem
Traditional light pipes require hardware such as gaskets, lock washers, and nuts for affixing to electronic device panels, which increases costs and complicates the installation process, making it time-consuming and requiring specific tools and knowledge.
Innovation Solution
A flexible light pipe assembly with an adapter that allows for a press-fit engagement between the light pipe and the printed circuit board, and between the light pipe and the electronic device panel, eliminating the need for additional hardware and simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hard plastic light pipes are used with hardware affixing (gasket, lock washer, nut), then the light pipe can be securely mounted to the panel, but the assembly cost increases and the installation process becomes complex and time-consuming
Solution Approach 1:
The patent extracts and eliminates the hardware components (gasket, lock washer, nut) from the light pipe assembly system. Instead of using separate affixing hardware, the invention integrates the mounting function directly into the light pipe structure itself, thereby reducing complexity while maintaining secure mounting capability
Solution Approach 2:
The invention merges the light pipe with the affixing mechanism by forming an integral portion of the light pipe that engages with the panel. This combining of functions eliminates the need for separate hardware components and simplifies the overall assembly structure
2Reliability
If traditional hard plastic light pipes with male threads are used, then the light pipe can be affixed to the panel with hardware, but the installation time increases and specific tools are required
Solution Approach 1:
The light pipe structure performs its own affixing function through an integral portion that engages with the panel without requiring external hardware or specialized tools. The design enables self-service mounting, eliminating installation time losses associated with traditional hardware assembly
3Stability of the object's composition
If traditional hard plastic light pipes are used, then the light pipe provides structural stability, but the light pipe cannot be easily deformed or flexed
Solution Approach 1:
The patent applies different material properties to different portions of the light pipe structure. The integral affixing portion is made of a flexible material that can deform to engage with the panel, while the main light transmission body maintains structural stability. This local differentiation of material properties resolves the contradiction between stability and adaptability
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 flexible light pipe assembly reduces assembly costs and simplifies the installation process by eliminating the need for hardware, while maintaining a watertight seal that complies with IP67 ratings.
Implementation Method 1
The light pipe assembly also includes at least one flexible light pipe which extends from the printed circuit board LED to the panel
Data Source
AI summary
A light pipe assembly is provided which complies with the International Electrotechnical Commission (IEC) IP ratings for dirt and water ingress while reducing the amount of hardware typically required to mount each light pipe. The light pipe assembly includes a light pipe and an adapter. Each adapter includes a vertically extending center channel which receives and connects a light pipe's first end to an LED mounted upon a printed circuit board (PCB). Each light pipe is intended to project through the hole of an electronic device's panel. Furthermore, each light pipe's second end has flange and a press-fit region, preferably in the form of circumferential ribs, which forms a press-fit engagement with a panel.