Edge-Mounted LED Clip Unit for PCB Orientation Flexibility
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Solution Overview
Problem
Existing mounting solutions for light sources on printed circuit boards (PCBs) are limited in flexibility and structural integrity, particularly for surface mount LEDs which are brighter and more diverse but typically mount normal to the PCB surface, making them less adaptable for low-profile applications like automotive components that require light emission in different orientations.
Innovation Solution
A clip unit comprising a housing portion made of insulative material and anode and cathode retention clips made of conductive material, allowing for secure edge mounting of light sources on PCBs with orthogonal electrical connections, enabling flexible orientation and increased structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If surface mount LEDs are mounted normal to the PCB surface, then brightness and light emission are improved, but adaptability to different orientations and mounting configurations is reduced
Solution Approach 1:
The patent transitions from traditional planar mounting (surface mount LEDs mounted normal to PCB surface) to three-dimensional edge mounting. The clip unit attaches to the edge of the PCB, allowing LEDs to be positioned in multiple orientations while maintaining optimal light emission. This dimensional change enables the same bright surface mount LEDs to be used in various mounting configurations including side-firing and top-firing orientations.
Solution Approach 2:
The clip unit is designed as a universal mounting solution that can accommodate different LED types (surface mount, side firing, twisted, butterfly) and orientations. The single clip unit design with adjustable retention clips provides multi-functional capability to secure various light source configurations, replacing the need for different specialized mounting solutions for different LED types and orientations.
2Strength
If traditional mounting solutions are used, then structural integrity may be maintained, but flexibility in mounting configurations is reduced
Solution Approach 1:
The retention clips are designed with elastic properties, allowing them to flex and adapt to different LED sizes and orientations while maintaining secure attachment. The dynamic nature of the elastic clips enables the rigid clip unit body to accommodate varying mounting configurations without compromising structural integrity, providing both strength and flexibility.
3Illumination intensity
If surface mount LEDs are used, then brightness and diversity are improved, but ease of manufacture for low-profile applications is reduced
Solution Approach 1:
The patent combines multiple functions into a single integrated clip unit: mechanical attachment to PCB edge, electrical connection provision, and LED retention. This consolidation simplifies the manufacturing process by reducing the number of separate components and assembly steps required, while still enabling the use of bright surface mount LEDs in low-profile applications.
Data Source
AI summary
A clip unit and an edge mount light emitting diode (LED) assembly comprising a clip unit. The clip unit provides a mounting structure for mounting a light source, such as an LED, to an edge of a printed circuit board (PCB). A surface mount LED, for example, can thus be easily mounted to the edge of the PCB so as to project light in a direction normal to the edge surface of the PCB, instead of the typical mounting orientation that allows for the projection of light normal to the primary surface of the PCB. The clip unit includes an anode retention clip and a cathode retention clip which are electrically isolated from one another within an insulative housing portion.