Tri-color LED Encoder with Integrated Injection Molded Substrate
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Solution Overview
Problem
Conventional encoders with single-color LEDs in electronic products face challenges with integration height and brightness, require additional manufacturing steps like soldering, and are not suitable for low-light environments, leading to increased costs and complexity.
Innovation Solution
An encoder with a tri-color LED that uses an independent red-green-blue LED loop for color mixing, integrated with a pushbutton switch and formed through plastic injection molding, eliminating the need for welding and simplifying manufacturing, allowing for compact size and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-color LED is mounted on the substrate, then the LED can be integrated into the encoder, but the integration of height and brightness becomes difficult and additional soldering steps are required
Solution Approach 1:
The patent combines the LED mounting function with the encoder substrate by integrating the LED directly into the encoder's circuit board structure. The LED is positioned within the encoder housing and electrically connected through the substrate, eliminating the need for separate mounting steps and reducing overall assembly complexity.
Solution Approach 2:
The encoder substrate serves multiple functions: it provides the structural base for the encoder, integrates the LED mounting position, and establishes electrical connections. This multi-functional design reduces the number of separate components and simplifies the manufacturing process.
2Productivity
If an LED is mounted using conventional methods, then the LED can be installed, but extra working steps like soldering are required which increase manufacturing time and cost
Solution Approach 1:
The patent replaces the conventional soldering process with a mechanical insertion method. The LED is designed to be inserted directly into a designated slot or holder on the encoder substrate, where it is secured mechanically and electrically connected through contact points, eliminating the need for heat-based soldering operations.
Solution Approach 2:
The LED is pre-positioned and pre-connected to the substrate in a simplified manner before final encoder assembly. The substrate includes pre-formed contact points and mounting structures that accommodate the LED, allowing for rapid installation without requiring complex soldering operations during final assembly.
3Adaptability or versatility
If a single-color LED is used, then the LED structure is simple, but it cannot change colors as required for different lighting conditions
Solution Approach 1:
The patent uses a tri-color LED that contains three separate light-emitting elements (red, green, and blue) within a single component. Each color element can be independently controlled through separate electrical connections, allowing the LED to display different colors or combinations of colors based on operational requirements.
Solution Approach 2:
The patent controls the color output by varying the electrical parameters (voltage or current) supplied to each color element of the tri-color LED. By adjusting these parameters, the LED can emit different colors or combinations of colors to suit different lighting conditions and operational states.
4Illumination intensity
If the LED is mounted separately on the substrate, then the LED can be installed, but the height and brightness integration becomes difficult
Solution Approach 1:
The patent nests the LED within the encoder housing structure, positioning it in a recess or designated area of the substrate. This nested arrangement ensures that the LED is properly positioned relative to the encoder components, optimizing both the height integration and the brightness output by placing the light source at the optimal location.
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 efficient color mixing and switching functions while avoiding high-temperature manufacturing processes, resulting in a lightweight, compact, and cost-effective encoder with improved illumination capabilities.
Implementation Method 1
an LED is mounted for producing lighting
Data Source
AI summary
An encoder with a tri-color LED includes an insulating base, five terminals, a conductive elastic piece, a tri-color LED assembly, an encoder substrate assembly, a conductive wiper assembly, and an insulated light shaft. The five terminals and the insulating base are formed integrally. The conductive elastic piece is received in a receiving chamber of the insulating base. The tri-color LED assembly is disposed in the receiving chamber. The encoder substrate assembly covers on both the conductive elastic piece and the tri-color LED assembly. The conductive wiper assembly is received in the encoder substrate assembly. The insulated light shaft passes through a through hole of the conductive wiper assembly and a through hole of the encoder substrate assembly. Thereby, through voltage variation of an independent tri-color LED loop, color mixing can be controlled, and that to combine the same with the encoder a function of lighting and marking can be achieved.