Configurable Light Pipe Frame for Dense PCB LED Mounting
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Solution Overview
Problem
Existing systems for mounting light pipes to printed circuit boards (PCBs) are difficult to install and consume excessive space, limiting the number of LEDs that can be mounted.
Innovation Solution
A configurable board mount light pipe array featuring a frame with longitudinally extending rails and adapters with tongue-and-groove connectors, allowing for a press-fit engagement with the PCB and efficient use of space, enabling easier installation and reduced space consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional adapters with pins are used to mount light pipes to PCB, then the light pipe can be securely affixed, but the space consumption on PCB increases and installation difficulty increases
Solution Approach 1:
The mounting system is divided into separate functional components: a frame structure that provides overall support and individual adapter elements that can be independently positioned. This segmentation allows the light pipe mounting function to be separated from the PCB hole requirement, reducing space consumption while maintaining secure attachment.
Solution Approach 2:
The patent introduces an intermediary frame structure that mediates between the PCB and the light pipes. Instead of directly mounting light pipes to the PCB through holes, the frame acts as an intermediary platform that can be mounted to the PCB and provides mounting points for multiple light pipes, thereby reducing the number of holes needed in the PCB.
2Reliability
If traditional adapters with pins are used to mount light pipes to PCB, then the light pipe can be securely affixed, but the installation complexity increases
Solution Approach 1:
The frame structure is pre-assembled with multiple adapter mounting positions before installation. This preliminary preparation allows for easier installation as the adapters can be quickly attached to the pre-positioned frame rather than individually mounting each light pipe to the PCB, reducing installation complexity while maintaining secure attachment.
3Adaptability or versatility
If multiple LEDs are mounted on PCB to provide visual indications, then the visual indication capabilities are enhanced, but the space required on PCB increases
Solution Approach 1:
The patent transitions the mounting approach from a two-dimensional PCB surface to a three-dimensional structure using a frame that extends vertically from the PCB. This dimensional change allows multiple light pipes to be mounted in close proximity without requiring proportional increases in PCB surface area, as they can be arranged in vertical or layered configurations on the frame structure.
Data Source
AI summary
A configurable board mount light pipe array is provided which includes four rails and one or more adapters. Each rail extends longitudinally and includes first and second ends which are connectable to the first and second ends of other rails to form a rectangular frame. The adapters are affixed within the middle of the rectangular frame. Each adapter includes a vertically extending center channel which extends entirely through the adapter. The top of each adapter's center channel includes a light pipe receptacle, and the bottom of the center channel includes an LED receptacle. The configurable board mount light pipe array further includes one or more light pipes which include first and second ends. The light pipes' first ends are positioned within a press-fit engagement within an adapter's light pipe receptacle and the light pipes' second ends are constructed to project through the holes of an electronic device panel.