Light Beacon Assembly Segmented Circuit Boards
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Solution Overview
Problem
Existing LED-based light beacons face challenges in heat management and assembly complexity due to the need for multiple LEDs and intricate wiring, which can lead to disconnection issues and reduced effectiveness in directing light over a 360-degree axis.
Innovation Solution
A light beacon assembly utilizing interconnected circuit boards with conductive tabs and receivers, eliminating the need for screws and wires, and leveraging natural heat dispersion to reduce the requirement for a heatsink, allowing for efficient light distribution using a Fresnel lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple LEDs are used to achieve high light output levels, then illumination intensity is improved, but device complexity and heat generation increase
Solution Approach 1:
The patent divides the circuit board into multiple segments, each carrying a portion of the LEDs. These segmented circuit boards are stacked and interconnected through conductive tabs, allowing the system to accommodate multiple LEDs for high light output while distributing the thermal and structural complexity across manageable segments.
Solution Approach 2:
The patent implements a nested structure where multiple circuit boards are stacked one on top of another, with each board containing LEDs and conductive tabs that interconnect with adjacent boards. This nesting approach consolidates multiple LED assemblies into a compact vertical arrangement, reducing overall device complexity while maintaining high illumination intensity.
2Illumination intensity
If multiple LEDs are positioned on a small central heatsink assembly, then illumination intensity is improved, but heat management becomes more difficult
Solution Approach 1:
The patent segments the LED assembly across multiple circuit boards stacked in a vertical arrangement. This segmentation distributes the heat-generating LEDs across multiple separated surfaces, increasing the effective heat dissipation area compared to a single compact heatsink assembly, thereby improving heat management while maintaining high light output.
Solution Approach 2:
The patent transitions from a planar arrangement of LEDs on a single heatsink to a three-dimensional stacked configuration of multiple circuit boards. This dimensional change vertically distributes the heat-generating components, utilizing the Z-axis for heat dissipation and reducing thermal concentration at any single location.
3Reliability
If screws and wire harnesses are used to assemble circuit boards, then electrical connection is achieved, but reliability decreases due to vibration and stress
Solution Approach 1:
The patent merges the mechanical fastening function and the electrical connection function into a single integrated conductive tab structure. The conductive tabs serve both to mechanically attach circuit boards together and to establish electrical connections, eliminating the need for separate screws and wire harnesses. This reduces assembly complexity and improves reliability by removing potential failure points from vibration and stress.
Solution Approach 2:
The patent extracts and eliminates the separate screw and wire harness components from the assembly, replacing them with an integrated conductive tab system. This extraction removes the sources of potential disconnection and failure, simplifying the assembly while enhancing reliability.
4Illumination intensity
If LEDs are positioned on a small cylindrical central assembly, then illumination intensity is improved, but ease of manufacture decreases due to assembly errors
Solution Approach 1:
The patent segments the LED assembly into multiple standardized circuit boards with identical conductive tab interfaces. This segmentation creates modular units that can be manufactured independently with consistent specifications, reducing assembly errors compared to positioning multiple LEDs on a single complex central assembly.
Solution Approach 2:
The conductive tabs are designed with universal functionality to serve both mechanical attachment and electrical connection purposes across all circuit boards. This universal design simplifies manufacturing by standardizing the interconnection interface, reducing the likelihood of assembly errors while maintaining high light output through multiple LEDs.
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 heat management needs, and ensures effective light dispersion over a 360-degree axis, enhancing the reliability and visibility of the light beacon.
Implementation Method 1
a light emitting diode mounted thereon
Implementation Method 2
light emitting diode technology has been implemented to take the place of xenon flash tubes
Implementation Method 3
Cylindrical Fresnel lenses have traditionally been used in connection with to direct light from the xenon flash tube outwardly around a 360 degree axis
Implementation Method 4
Cylindrical Fresnel lenses have traditionally been used
Implementation Method 5
each of the plurality of circuit boards having a conductive tab extending from a first side
Data Source
AI summary
The present application relates to a light beacon, light beacon assembly, and methods of its construction. In one aspect, a light beacon assembly includes a housing including a base and a lens cooperating to enclose an interior volume, the lens having a generally cylindrical shape. The assembly also includes a plurality of circuit boards positioned within the interior volume, where each of the plurality of circuit boards having a conductive tab extending from a first side, a conductive tab receiver near a second side, and a light emitting diode mounted thereon. The plurality of circuit boards are each positioned within the interior volume and extend perpendicularly from the base such that the tab of each circuit board is received at the tab receiver of an adjacent circuit board. The plurality of circuit boards are interconnected to form a structure having light emitting diodes oriented outwardly toward the lens.