PCB Aperture Illumination for Compact Barcode Scanners
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Solution Overview
Problem
As complex devices become smaller and thinner, there is a challenge in providing enough space for light-emitting diode contacts, wires, and beam alignment while maintaining the appropriate dimensions for shaping the light beam.
Innovation Solution
The integration of apertures and receptacles in a printed circuit board, combined with a flexible or foldable circuit board, allows for precise alignment and beam shaping of light-emitting diodes, using a lens system to project a sharp-edged illumination pattern, and the use of three-dimensional fabrication techniques for high precision and compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If complex devices are made smaller and thinner, then device size is reduced, but space for contacts, wires, and beam alignment is insufficient
Solution Approach 1:
The patent merges the aperture structure and receptacle structure into a single integrated printed circuit board component. The receptacle is formed as an recessed cavity within the board, and the aperture is created as a through-hole or opening in the same board structure, eliminating the need for separate alignment components and reducing overall device volume while maintaining functional separation.
Solution Approach 2:
The patent utilizes the vertical dimension (Z-axis) of the printed circuit board by creating recessed receptacles that extend into the board thickness. This allows light-emitting diodes to be positioned at precise depths, enabling proper beam alignment through the aperture while maintaining a compact overall footprint in the X-Y plane.
2Volume of moving object
If aperture size is reduced for compact design, then device size is reduced, but alignment precision of light-emitting diodes becomes more difficult
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the aperture structure, such as positioning protrusions or tapered sections that guide the light-emitting diode into correct alignment during assembly. This pre-built guidance system ensures precise positioning even when the aperture itself is small, eliminating the need for post-assembly alignment adjustments.
3Illumination intensity
If beam shaping is improved for sharp edges, then illumination quality is improved, but device complexity increases
Solution Approach 1:
The printed circuit board serves multiple functions simultaneously: it provides structural support, electrical connectivity, mechanical alignment (through the receptacle), and optical beam shaping (through the aperture geometry). By making the board itself multi-functional, the patent achieves sharp-edged illumination without adding separate beam-shaping components that would increase device complexity.
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 enables precise alignment and efficient light projection with sharp edges and uniform intensity, maintaining mechanical robustness and compact dimensions, suitable for applications like scanners and barcode readers.
Implementation Method 1
using a lens system to project a sharp-edged illumination pattern
Data Source
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AI summary
A complex device (400) that integrates a beam shaping aperture in a printed circuit board 430 of the complex device (e.g., scanner or barcode reader or optical module) is provided. The complex device (400) has a light-emitting diode (420) pattern projection system. The pattern projection system includes one or more light-emitting diodes (420) and a printed circuit board (430). The printed circuit board (430) has one or more apertures and one or more receptacles. The one or more receptacles are positioned behind the aperture and receive the one or more light-emitting diodes. The printed circuit board (410 and 430) with receptacle offer self-alignment for the light emitting diodes (420). The beam shaping aperture in front of the light-emitting diodes (420) allows light to pass through the aperture that is part of the printed circuit board layer of the complex device (400).