Power Tool Optical Fiber Illumination Without Extra Wiring

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Solution Overview

Problem

Power tools require additional circuitry and wiring for LEDs to function as status indicators or work lights, which occupies valuable space and increases manufacturing complexity and cost.

Innovation Solution

Incorporation of optical fibers to transmit light from internal light sources to external indicators or work areas, eliminating the need for additional circuitry and wiring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If LEDs are positioned within the housing to provide status indicators or work light, then illumination function is achieved, but additional circuitry and wiring are required which occupy space and increase complexity

Engineering Contradiction:

Improvelight outputVSAvoidcircuitry and wiring

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent replaces the conventional electrical circuitry and wiring system with an optical fiber transmission system. Instead of using LEDs mounted on circuit boards with electrical connections, the invention uses optical fibers to transmit light from internal light sources to external indicator locations, eliminating the need for complex electrical wiring and circuit boards while maintaining the illumination and indication functions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces optical fibers as intermediary elements to transfer light energy from the light sources inside the housing to the indicator locations on the external surface. These optical fibers act as mediators that carry the illumination function without requiring electrical connections, thereby reducing device complexity while preserving the intended light output and indication capabilities.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Illumination intensity

If LEDs are positioned within the housing to provide status indicators or work light, then illumination function is achieved, but valuable housing space is occupied by additional circuitry and wiring

Engineering Contradiction:

Improvelight outputVSAvoidhousing space

Core Design Contradiction:

Illumination intensityVSVolume of moving object

Solution Approach 1:

The patent replaces the space-consuming electrical circuitry and wiring with compact optical fiber bundles. The optical fibers occupy significantly less volume within the housing compared to the circuit boards, wiring harnesses, and associated mounting structures required for LED-based illumination systems, thereby freeing up valuable housing space for other components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the bulky electrical circuitry and wiring from the housing interior by replacing it with thin optical fibers. This extraction of unnecessary electrical components eliminates the need for large circuit boards and extensive wiring, significantly reducing the volume occupied by illumination-related components within the housing.

Inventive Principle:

Principle #2Taking out (Extraction)

3Illumination intensity

If LEDs are used for status indicators or work light, then illumination function is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvelight outputVSAvoidmanufacturing complexity and cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent replaces the complex electrical assembly process involving circuit board mounting, LED installation, and wiring connections with a simpler optical fiber integration process. The optical fibers can be pre-assembled and directly coupled to light sources, eliminating multiple manufacturing steps such as PCB assembly, soldering, and electrical wiring, thereby reducing manufacturing complexity and associated costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses optical fibers as intermediary light transmission elements that simplify the manufacturing process. Instead of requiring precise electrical connections and circuit board assembly, the optical fibers provide a straightforward light transmission path that can be integrated more easily during manufacturing, reducing both the complexity and cost of the assembly process.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Saves space, reduces manufacturing complexity, and lowers costs by using optical fibers to convey light externally without additional circuitry and wiring.

Implementation Method 1

Incorporation of optical fibers to transmit light from internal light sources to external indicators or work areas

Methodology Applied

Scientific EffectOptical fiber light transmission: Optical Fibre

Data Source

PatentUS12429213B2Power tool utilizing optical fibers to output light

Publication Date: 2025.09.30 MILWAUKEE ELECTRIC TOOL CORP

AI summary

A power tool includes a primary housing, and a motor situated within the primary housing. The power tool also includes a circuit board located within the primary housing, and a light source mounted to the circuit board. The power tool also includes an optical fiber including a first end and a second end. The first end may be coupled to the light source and may be configured to receive light generated by the light source. The second end may be configured to emit the light to an outside of the primary housing to provide a status indication to a user and/or to illuminate a work area.