Claims:We Claim:

1. A lamp (100) with soldered PCBs, the lamp (100) comprising:
a housing (102);
a first printed circuit board (PCB) (104), configured to power a first set of Light emitting diodes (LEDs) (1040);
a second PCB (106), soldered at an end of the first PCB (104), arranged perpendicularly to the first PCB (104), configured to power a second set of LEDs (1060);
a reflector (108), configured to reflect light from the first set of LEDs (1040);
an extension (112) configured to cover the first PCB (104), the second PCB (106), the first set of LEDs (1040), the second set of LEDs (1060), and the reflector (108) and connected with the housing (102); and
an inner lens (110) fixed over the extension (112), facing the second set of LEDs (1060);
wherein the second set of LEDs (1060) is configured to light the inner lens (110).
2. The lamp (100) as claimed in claim 1, wherein the reflector (108) comprises a first reflector surface arranged above the first PCB (104) and a second reflector surface arranged below the first PCB (104); wherein the first reflector surface and the second reflector surface are facing the first set of LEDs (1040).
3. The lamp (100) as claimed in claim 2, wherein the first reflector surface and the second reflector surface are configured to direct light from the first set of LEDs (1040).
4. The lamp (100) as claimed in claim 1, wherein the housing (102) is configured to accommodate the first PCB (104), the second PCB (106), the first set of LEDs (1040), the second set of LEDs (1060), the reflector (108), a grommet (118), and wires.
5. The lamp (100) as claimed in claim 1, wherein the inner lens (110) comprises a first inner lens (154) and a second lens.
6. The lamp (100) as claimed in claim 5, comprising a third PCB (122) configured to power a third set of LEDs and a fourth PCB (124) configured to power a fourth set of LEDs;
wherein the third PCB (122) along with the third set of LEDs, is arranged on the left of the first PCB (104), facing the first inner lens (154) and the fourth PCB (124) along with the fourth set of LEDs, is arranged on the right of the first PCB (104), facing the second inner lens (156).
7. The lamp (100) as claimed in claim 1, comprising an outer lens (114) covering the inner lens (110), the first PCB (104), the second PCB (106), the first set of LEDs (1040), the second set of LEDs (1060), and the reflector (108), connected with the housing (102).
8. The lamp (100) as claimed in claim 7, wherein the light from the first set of LEDs (1040), passes through one or more slots (152) provided in the extension (112) and adapted to glow the outer lens (114).

Dated this the 13th day of August 2021.

[VIVEK DAHIYA]
AGENT FOR THE APPLICANT – IN/PA 1491.
, Description:FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10 and rule 13]

A LAMP WITH SOLDERED PCBS

We, Lumax Industries Limited, an Indian company, having a registered office at 2nd Floor, Harbans Bhawan-II, Commercial Complex, Nangal Raya, New Delhi-110046, India.

The following specification describes the invention and the manner in which it is to be performed.
FIELD OF THE INVENTION
Embodiment of the present invention relates to automotive lighting systems and more particularly to a lamp with soldered PCBs.
BACKGROUND OF THE INVENTION
For a LED lamp, PCBs assembly plays a key role. As one Lamp has different functions, so might be different PCBs for that, Sometimes due to critical design of Tail lamp, we have to mount different PCBs for different functions at different locations, so this requires more screws & more space for mounting these PCBs and increase assy. time and reduce production. On other hand, for different functions different PCBs are used e.g. For Tail, Stop functions separate PCBS are used, for joining these PCBs with each other’s we need wires and connectors/couplers.
While Connecting PCBs with wires, soldering separate wire is challenging & requires skilled workers. Assembly is complicated with PCBs joint with wires. Most of times to made routing of wires for assembly to avoid sagging of wire, which creates extra cost in tooling. Many times wire breaks while assembly. During soldering wires burn out issue occurs. Further, number of process increases like wire cutting, peeling, tinning etc. which increase cost & and requires extra manpower & machines. Sometimes coupler are used to join PCBs which are very expensive.
Therefore, there is a need for a lamp with soldered PCBs, which can overcome deficiencies and limitations of the prior arts.
OBJECT OF THE INVENTION
An object of the present invention is to provide a lamp with soldered PCBs.
Another object of the present invention is to provide an easy to assemble lamp.
Yet another object is to provide the lamp where No wires is used so, no sleeve, tape and clip required.
Yet another object is to provide the lamp with less chance of burn out as compare to wire soldering.
Yet another object is to provide the lamp having cheap solution as no peeling cutting required so less man power & machine required.
Another object of the present invention is to provide a compact size to the lamp
Yet another object of the present invention is to reduce number of components in the lamp.
Yet another object of the present invention is to reduce weight and cost of Lamp.
Yet another object of the present invention is to reduce assembly time of the lamp.
Yet another object of the present invention is to provide easy assembly resulting in reduced operator fatigue.
Yet another object of the present invention is reduction in E-waste and save environment from toxic emission.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simple manner, which is further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the subject matter, nor to determine the scope of the invention.
According to an aspect of the present invention, there is provided a lamp with soldered PCBs, the lamp comprises a housing, a first printed circuit board (PCB), configured to power a first set of Light emitting diodes (LEDs), a second PCB, soldered at an end of the first PCB, arranged perpendicularly to the first PCB, configured to power a second set of LEDs, a reflector, configured to reflect light from the first set of LEDs, an extension configured to cover the first PCB, the second PCB, the first set of LEDs, the second set of LEDs, and the reflector and connected with the housing, and an inner lens fixed over the extension, facing the second set of LEDs. Further, the second set of LEDs is configured to light the inner lens.
In accordance with an embodiment of the present invention, the reflector comprises a first reflector surface arranged above the first PCB and a second reflector surface arranged below the first PCB; wherein the first reflector surface and the second reflector surface are facing the first set of LEDs.
In accordance with an embodiment of the present invention, the first reflector surface and the second reflector surface are configured to direct light from the first set of LEDs.
In accordance with an embodiment of the present invention, the housing is configured to accommodate the first PCB, the second PCB, the first set of LEDs, the second set of LEDs, the reflector, a grommet, and wires.
In accordance with an embodiment of the present invention, the inner lens comprises a first inner lens and a second lens.
In accordance with an embodiment of the present invention the lamp comprises a third PCB configured to power a third set of LEDs and a fourth PCB configured to power a fourth set of LEDs. Further, the third PCB along with the third set of LEDs, is arranged on the left of the first PCB, facing the first inner lens and the fourth PCB along with the fourth set of LEDs, is arranged on the right of the first PCB, facing the second inner lens.
In accordance with an embodiment of the present invention the lamp comprises an outer lens covering the inner lens, the first PCB, the second PCB, the first set of LEDs, the second set of LEDs, and the reflector, connected with the housing.
In accordance with an embodiment of the present invention, the light from the first set of LEDs, passes through one or more slots provided in the extension and adapted to glow the outer lens.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments.
These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:
Fig. 1 illustrates an exploded view of a lamp, in accordance with an embodiment of the present invention;
Figs. 2 illustrates a first PCB soldered to a second PCB, in accordance with an embodiment of the present invention; and
Fig.3 illustrates the lamp with inner and outer lens, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
While the present invention is described herein by way of example using embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modification/s, equivalent/s and alternative/s falling within the scope of the present invention as defined by the appended claim. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claim. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must).
Further, the words "a" or "an" means "at least one” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including", "comprising", "having", "containing", or "involving" and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the likes are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
In this disclosure, whenever an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element or group of elements with transitional phrases “consisting of”, “consisting”, “selected from the group of consisting of”, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.
This invention described herein may be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.
Figure 1 illustrates an exploded view of a lamp, in accordance with an embodiment of the present invention. As shown in figure 1, the lamp (100) comprises a housing (102), a first printed circuit board (PCB) (104), a second PCB (106), a first set of light emitting diodes (LEDs) (1040), a second set of LEDs (1060), a reflector (108), an extension (112), an inner lens (110), and an outer lens (114). Further, figure 2 illustrates a first PCB (104) soldered to a second PCB (106), in accordance with an embodiment of the present invention. As shown in figure 2, the second PCB (106) is soldered at an end of the first PCB (104). The second PCB (106) is arranged perpendicularly to the first PCB (104).
In accordance with an embodiment of the present invention, the housing (102) may comprise one or more cavity to facilitate screws (116). Further the housing (102) may comprise a plurality of ribs (not shown). The plurality of ribs may be made of, but not limited to, non-corrosive metal, plastic, PVC, PMMA, etc. The housing (102) may be configured to accommodate the first PCB (104), the second PCB (106), the first set of LEDs (1040), the second set of LEDs (1060), the reflector (108), a grommet (118), and wires. Further, the housing (102) may configured to receive a light source. The housing (102) may comprise an opening to facilitate the light source.
In accordance with an embodiment of the present invention, the extension (112) is configured to cover the first PCB (104), the second PCB (106), the first set of LEDs (1040), the second set of LEDs (1060), and the reflector (108) and connected with the housing (102). The extension (112) may be connected with the housing (102) using may be, but not limited to snap fit mechanism, screws (116), nuts bolts, glue, rivets etc.
In accordance with an embodiment of the present invention, the housing (102) may be configured to secure the reflector (108), the first PCB (104) and the second PCB (106), the first set of LEDs (1040), the second set of LEDs (1060), the extension (112), and the inner lens (110). The lamp (100) may secure the first PCB (104) and the second PCB (106), packed in between the housing (102) and the reflector (108). Any of the first PCB (104) and the second PCB (106), may be selected from a group comprising of, but not limited to, a single layer, double layer, multi-layer, Rigid-PCB, flexible, Rigid-Flex, High-frequency, Aluminium-backed printed circuit board, and the like. The first PCB (104) and the second PCB (106), may be envisaged to comprise a plurality of holes on surfaces. The first set of LEDs and the second set of LEDs may be embedded in the first PCB (104), and the second PCB (106) respectively. The LEDs may be single chip LEDs configured as a light source. The light source may be used for indicating stoppage of vehicle and/or a position of the vehicle.
In accordance with an embodiment on the present invention, the reflector (108) may be disposed inside the housing. The material for the reflector (108) may have the property of being highly reflective, anti-corrosive, and temperature resistant. The material may be, but not limited to, polycarbonate (PC), polypropylene (PP), polybutylene terephthalate, nylon, Acrylonitrile Butadiene Styrene (ABS), Polymethyl Methacrylate (PMMA), and Polyethylene terephthalate (PET), bulk moulding compound (BMC), acrylic mirror, glass mirror, polished metal, and chromic reflector (108). In accordance with an embodiment of the present invention the reflector (108) may comprise a first reflector surface arranged above the first PCB (104). The reflector (108) may further comprise a second reflector surface arranged below the first PCB (104). The first reflector surface and the second reflector surface faces the first set of LEDs (1040).
In accordance with an embodiment of the present invention, the lamp (100) may comprise a third PCB (122) configured to power a third set of LEDs (not shown). The lamp (100) may further comprise a fourth PCB (124) configured to power a fourth set of LEDs (not shown). The housing (102) may further be configured to secure the third PCB (122), the fourth PCB (124), the third set of LEDs and the fourth set of LEDs. The third PCB (122) along with the third set of LEDs, is arranged on the left of the first PCB (104). The third set of LEDs may be facing the first inner lens (154). Further, the fourth PCB (124) along with the fourth set of LEDs may be arranged on the right of the first PCB (104). The fourth set of LEDs may be facing the second inner lens (156).
In accordance with an embodiment of the present invention, the lamp (100) may comprise an outer lens (114) covering the inner lens (110), the first PCB (104), the second PCB (106), the first set of LEDs (1040), the second set of LEDs (1060), and the reflector (108), connected with the housing (102). Further figure 3 illustrates the lamp (100) with inner and outer lens (114), in accordance with an embodiment of the present invention. As shown in figure 3, the inner lens (110) comprises a first inner lens (154) and a second lens. The inner lens (110) may be fixed over the extension (112), facing the second set of LEDs (1060). The outer lens (114) and the inner lens (110) may be made of, but not limited to, polycarbonate (PC), polypropylene (PP), polybutylene terephthalate, nylon, Acrylonitrile Butadiene Styrene (ABS), Polymethyl Methacrylate (PMMA), and Polyethylene terephthalate (PET), bulk moulding compound (BMC). The outer lens (114) may be connected with the housing (102) using may be, but not limited to snap fit mechanism, screws (116), nuts bolts, glue, rivets etc.
In an additional or alternative embodiment, the inner lens (110) and/ or the out lens (114) may comprise a plurality of etched surfaces. The plurality of etched surfaces may have a plurality of facets such as slope facets and draft facets at predefined angles that may scatter light. The scattered light provides better light output. The facets then aims the light passing through it in a specific direction, such that all the beams from all the facets together make the requested external distribution of light. The output light falls over without directly visible to a vehicle behind.
In accordance with an embodiment of the present invention, the housing (102) may further comprises a connector, grommet (118), plug (120), screw, and wires. The connector may be configured to provide an electrical connection between a power source and the first PCB (104), the second PCB (106), the third PCB (122), and the fourth PCB (124). The connector may be electrically connected with the first PCB (104), the second PCB (106), the third PCB (122), and the fourth PCB (124) through the wire.
In an embodiment, the first PCB (104), the second PCB (106), the third PCB (122), and the fourth PCB (124) may be controlled by a switch (not shown). The switch may be, but not limited to, a Single Pole Single throw (SPST) switch, a single pole double throw (SPDT) switch, a double pole, single throw (DPST) switch, a double pole double throw (DPDT) switch. The switch may be operated by a user. The switch may be placed in a place easily operable by the user. The switch may be placed may be, but not limited to, on a handlebar, on dashboard, on steering wheel, on the lamp (100) or anyplace of a vehicle easily approachable to a user.
The invention works in following manner:
The first PCB (104) is configured to power the first set of LEDs (1040). The reflector (108) is configured to reflect light from the first set of LEDs (1040). The first reflector surface and the second reflector surface are facing the first set of LEDs (1040). In accordance with an embodiment, the first reflector surface and the second reflector surface are configured to direct light from the first set of LEDs (1040). The light from the first set of LEDs (1040) passes through one or more slots (152) provided in the extension (112) and adapted to glow the outer lens (114).
Further, the second PCB (106) arranged perpendicularly to the first PCB (104) is configured to power the second set of LEDs (1060). The second set of LEDs (1060) is configured to light the inner lens (110). The inner lens (110) comprises the first inner lens (154) and the second inner lens (156). The third PCB (122) along with the third set of LEDs, is arranged on the left of the first PCB (104), facing the first inner lens (154). The third PCB (122) is configured to power the third set of LEDs to glow the first inner lens (154). Further, the fourth PCB (124) along with the fourth set of LEDs, is arranged on the right of the first PCB (104), facing the second inner lens (156). The fourth PCB (124) is configured to power the fourth set of LEDs to glow the second inner lens (156).
The first PCB (104) and the second PCB (106), on actuation of the switch, supplies the electrical power to the first set of LEDs (1040) and the second set of LEDs (1060). The first set of LEDs (1040) and the second set of LEDs (1060) produce light. The light from the first set of LEDs (1040) and the second set of LEDs (1060) reflects from reflector (108) and the inner lens (110). The reflected light passes through the reflector (108) and may be through the plurality of etched surfaces. In an additional or alternative embodiment, the light from the second set of LEDs (1060) may be configured to pass through the inner lens (110). Further the light from the third set of LEDs and the fourth set of LEDs may be configured to pass through the first inner lens (154) and the second inner lens (156).
The present invention provides a number of advantages. Firstly, the present invention saves extra cost of wires, different process like cutting peeling, tinning of wires so requires less manpower & machine, No connectors required so cheap solution. Some of the benefits also includes ease of assembling. Further, no wires is used so, no sleeve, tape and clip required. Furthermore, less chance of burn out as compare to wire soldering. In addition, cheap solution as no peeling cutting required so less man power & machine required. Moreover, the cost of the lamp (100) is reduced. Time of assembly is reduced due to less complicated and easy design. Easy assembly results in reduced operator fatigue. Further, Strength of the assembly is more than that of spring fixing. Furthermore, the compact size and less power consumption of the present invention make it a cost-effective solution to the problems of the prior art.
Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be provided broadest scope consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.