Reverse-Mount LED Appliance Interface on Single-Sided PCB
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Solution Overview
Problem
Conventional user interfaces for appliances, such as seven-segment displays and through-hole LEDs, are inefficient due to large footprint, increased manufacturing time and costs, and power consumption, while LCD replacements complicate programming and reliability.
Innovation Solution
A user interface system utilizing reverse mount light emitting diodes (LEDs) for both numerical and non-numerical information display, integrated on a single-sided printed circuit board with a light module, diffuser screen, and IDO film, allowing for reduced size, cost, and improved design flexibility and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional seven-segment display modules and through-hole LEDs are used, then numerical and non-numerical information can be communicated, but the footprint is large and manufacturing time and costs increase
Solution Approach 1:
The patent applies universality by using the same LED type (reverse mount LEDs) for both numerical display in seven-segment configurations and non-numerical indicator functions. This multi-functional approach eliminates the need for separate thru-hole LEDs, reducing the number of different device elements and simplifying the user interface design while maintaining the ability to communicate both numerical and non-numerical information
Solution Approach 2:
The patent merges the functions of numerical display and non-numerical indicators into a single integrated user interface structure. By combining both display functions using the same reverse mount LED technology and mounting them on the same printed circuit board, the overall footprint is reduced compared to having separate display modules
2Quantity of substance
If conventional seven-segment display modules and through-hole LEDs are used, then information can be communicated, but manufacturing time and costs increase
Solution Approach 1:
By using reverse mount LEDs that serve both numerical and non-numerical display functions, the manufacturing process is simplified. The same component type and mounting procedure (surface mount on single-sided PCB) is used throughout, eliminating the need for separate thru-hole LED installation steps, which reduces manufacturing time and costs
Solution Approach 2:
The patent replaces the traditional mechanical insertion method (thru-hole mounting) with surface mount technology. Reverse mount LEDs are mounted on the surface of a single-sided printed circuit board, which is a more efficient and automated-friendly process compared to drilling, inserting, and soldering thru-hole components, thereby improving manufacturing productivity
3Device complexity
If LCD is used to replace seven-segment display and through-hole LEDs, then all user information can be communicated by one display, but programming requirements increase and power consumption increases
Solution Approach 1:
Instead of using a single complex LCD display that requires extensive programming to show all information types, the patent inverts the approach by using multiple simple LED indicators. Each reverse mount LED can be independently controlled to display different information, eliminating the need for complex display programming while maintaining the ability to communicate all user information
Solution Approach 2:
The patent uses simple, low-cost LED indicators rather than an expensive LCD module. LEDs are simpler devices with fewer programming requirements and lower power consumption. While individually simple, multiple LEDs collectively provide all necessary information display functions without the complexity and power demands of an LCD system
4Device complexity
If LCD is used to replace seven-segment display and through-hole LEDs, then all user information can be communicated by one display, but power consumption increases
Solution Approach 1:
The patent replaces the power-hungry LCD with multiple simple LED indicators. LEDs consume significantly less power than LCD displays, especially when displaying static or periodically updated information. This substitution maintains all necessary information display capabilities while dramatically reducing power consumption
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
The solution enables a compact, reliable, and cost-effective user interface that simplifies manufacturing and reduces power consumption while maintaining effective information communication, addressing the limitations of conventional systems.
Implementation Method 1
A user interface system utilizing reverse mount light emitting diodes (LEDs) for both numerical and non-numerical information display
Data Source
AI summary
A system and method of displaying appliance information to a user is provided. Reverse mount LEDS may be used in a seven segment configuration and correlating to any other icon or indicator. The reverse mount LEDs may be mounted on single sided printed circuit board to form an appliance user display.