Surface-Mount LED Protector with Segmented Cover and Support
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Solution Overview
Problem
Surface-mount light-emitting diodes (LEDs) are prone to mechanical damage during assembly, especially in tight spaces such as driver monitoring systems, where precise handling is required.
Innovation Solution
A protector comprising a support portion and a cover portion is designed to be mechanically connected to a circuit carrier, with openings for the LEDs to allow light emission while preventing accidental access and damage, using a snap connection or soldering for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protector is added to protect LEDs during assembly, then the mechanical protection and reliability are improved, but the device complexity and space requirements increase
Solution Approach 1:
The protector is divided into two separate components: a support portion that connects to the circuit carrier and a cover portion that provides protection. This segmentation allows each part to be optimized for its specific function while simplifying the overall assembly process and reducing complexity.
Solution Approach 2:
The cover portion is designed to be mechanically connected to and supported by the support portion, creating a nested structure where the cover portion fits over the support portion. This nesting approach provides effective protection while minimizing the overall space required and avoiding unnecessary structural complexity.
2Reliability
If the cover portion is positioned at a larger distance from the circuit carrier surface, then the mechanical protection is improved, but the space requirements and device dimensions increase
Solution Approach 1:
The support portion includes a sidewall that connects to the circuit carrier and a pass-through section that allows the LEDs to protrude through. This dynamic structure provides the necessary protection distance while accommodating the LED positioning and light emission requirements without excessive space consumption.
Solution Approach 2:
The protector utilizes the vertical dimension perpendicular to the circuit carrier surface to provide protection, with the cover portion extending at a larger distance from the surface. This dimensional approach allows effective protection while maintaining a compact footprint on the circuit carrier plane.
3Ease of operation
If openings are provided in the cover portion for light emission, then the functionality is maintained, but the structural integrity and protection effectiveness are reduced
Solution Approach 1:
The cover portion has one or more openings that are strategically positioned to allow light from the LEDs to pass through while maintaining protection in other areas. This local quality approach ensures that the openings are simple through-holes positioned precisely where needed, providing both functionality and protection without unnecessary structural compromise.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A protector (1) for surface-mounted LEDs (6) includes a support portion (10) to connect to a circuit carrier (80), e.g., a PCB, on which the LEDs (6) are mounted, and a cover portion (20) supported by and connected to the support portion (10). The cover portion (20) has one or more openings (21) for radiation from the LEDs (6) to pass through. The protector (1) is mounted on the circuit carrier (80) in such a way that the openings (21) of the cover portion (20) are aligned with the LEDs (6).