Guide To Installing LEDs and Light Pipes

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Guide to Installing LEDs

and Light Pipes
www.bivar.com
Guide to Installing LEDs and Light Pipes
Introduction
Light pipes play an essential role in a wide array of devices, whether
supporting indication, functional illumination, or backlighting. Light pipes
create the desired distribution of light at the point of use. They bring output
from the LED to the panel with minimum loss. They add flexibility to board
design. With light pipes, LEDs don’t have to be placed adjacent to the panel.
They can be elsewhere on the board or even in a different orientation from the
indication point. Light pipes increase the visibility, modify the visibility, and
modify the LED output to optimize visibility for the application, whether the
light needs to be visible only from the front or over a broad angle. Light pipes
can include ingress protection ratings as high as IP68.
It’s important to remember that light pipe performance is only as effective as

the installation. When the device is properly specified and installed, it will give
the desired results.
Light pipe types

Light pipes can be classified by mounting style, as panel-mount or board-mount types. Panel-mount light
pipes are threaded through holes in the panel. They are held in place with crush ribs that form a friction
fit with the panel hole or with a lens cap inserted through the panel hole. Board-mount light pipes are
attached to the PCB using an adapter. Light pipes are available as rigid and flexible (optical-fiber based)
versions (see Figure 1). Rigid light pipes can be either panel mounted or board mounted; flexible light pipes
can only be board mounted.
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Figure 1: Light pipes can be divided into rigid (left) and flexible (right). Note: rigid light pipes can be molded into a variety
of three-dimensional shapes, as well as the straight light pipe shown. [Source: Bivar]
Design Considerations
Effective installation starts with specifying the design and components. To optimize coupling, the LED
should generate a forward-directed output distribution. The light pipe needs to be matched to the LED –
wide enough to maximize input coupling but not so wide that input light undergoes excessive reflections
during propagation, which can lead to optical losses.
The mechanical design is critical to both performance and efficient installation. Tolerances for hole diam-
eters in the panel and in the PCB need to match the data sheets for the parts. In the case of panel-mount
light pipes, the panel thickness and length of the light pipe should be specified to leave a safe minimum
distance between the end face and the LED. Machining and assembly tolerances need to ensure that
spacing is preserved, to prevent damage and loss during the assembly process.
In the case of the board-mount light pipes, any machining tolerances for holes drilled for the adapters
need to meet specifications. The mounting structures for the board and the housing need to be held to
tolerances that will preserve light pipe-to-LED spacing. From a performance standpoint, it’s essential that
board mounting structures or alignment features ensure that the light pipe is centered over the LED.
General installation process

Installation of light pipes varies depending on mounting type. In general, light-pipe installation is a manual
process, but it’s fast, easy, and requires no special tooling. In certain cases, assemblers may choose to build
a jig to simplify assembly. Light-pipe assembly can also be automated.
Successful installation and performance start with proper preparation. Surfaces must be clean and dry,
with no dust or material shavings. Polymers and plastics are insulators and can build up charge. Technicians
should be sure to follow procedures for ESD protection.
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Panel mounting
Panel-mount light pipes are attached to the panel. They are not in contact with the LED or PCB, but hover
just above them. OEMs can choose among several options to get the degree of stability and protection that
best suits their application.
Panel-mount light pipes can be divided into front mount and rear mount types.
Front mounting options

In a front-mount, panel-mount light pipe, the light pipe is inserted through a hole in the panel from the
front, typically by hand. Front-mount, panel-mount light pipes are straight and rigid. They may incorporate
lenses to either enhance or restrict visibility. They are available in a variety of shapes and functions (see
Figure 2). The lenses commonly feature flanges to limit travel. They may incorporate crush ribs to hold the
assembly in place with a friction fit. There’s no need for adhesive.
Figure 2: Front-mount light pipes are available in a variety of shapes with different characteristics. Shown here are (from
left) a square light pipe with crush ribs, a countersunk light pipe, light pipe with a high-visibility lens, and a cylindrical pipe
with crush ribs. [Source: Bivar]
Procedure
1. Prep surfaces and components. Put ESD protection in place.
2. Press light pipe through hole in panel until lens flange meets the front surface of panel
and the crush ribs create a friction fit.
CAUTION: Do not remove and reinsert the light pipe. Crush ribs are good for only one
insertion – once the ribs are deformed, they can no longer provide a secure fit.
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IP-rated front-side panel mounts

Front-mount light pipes can provide protection in multiple ways (see Figure 3). A gasket can be added to
a lens cap to seal the aperture. A hex nut can be used with a threaded lens cap to increase protection, or
other mechanical elements such as locking washers can be included.
Figure 3: Front-mount, panel-mount light-pipe options include (from left) simple friction-fit versions, threaded designs
for enhanced ingress protection, or assemblies incorporating gaskets and locking washers for shock and vibration
resistance. [Source: Bivar]
Procedure for IP54 rated version

1. Thread gasket over light pipe (see Figure 4).
2. Insert light pipe into panel hole.
3. Press firmly to seat gasket; crush ribs will maintain friction fit for an IP54 rating.
Figure 4: The PLW5 front mounted light pipe uses crush ribs and a sealing gasket to achieve an IP54 rating. [Source: Bivar]
For more demanding applications with higher levels of contamination and/or greater shock and vibration,
users have the option of threaded light pipes that increase protection to IP67 and add vibration resistance.
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1. Thread sealing ring over the light pipe until it is snug against the flange of the lens cap
(see Figure 5).
2. Insert light pipe into panel hole.
3. Thread washer onto light pipe on rear side of panel.
4. Place flat side of nut against washer. Tighten by hand until there is resistance. Hold
the head of the light pipe still and use a torque wrench to tighten the nut to 6-7 in-oz.
Figure 5: The PLTR front mount, panel-mount light pipe combines a sealing ring on the front side with a washer and nut on
the rear side to achieve an IP67 rating. [Source: Bivar]
Figure 6: Rear-mount light pipes like the PLP1 frequently have collars to restrict travel and crush ribs to provide a secure fit.
[Source: Bivar]
Rear-mounting
In the case of a rear-mount light pipe, the indication end of the light pipe is pressed through the hole in the
panel from the back side. A retention ring generally restricts length of travel (see Figure 6). Crush ribs can
provide a friction fit. Rear-mounting provides only limited stability – they are best for illuminating overlays
or in other protected applications not subject to significant shock or vibration.
Procedure
1. Press indication end of light pipe through the hole until it reaches the retention ring.
The crush ribs will provide a friction fit.
2. Install PCB, taking care to avoid contact between the LED and the end of the light
pipe.
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Hybrid system – front-mount lens and rear-mount light pipe

For systems that need protection from both dust and moisture and shock and vibration, hybrid systems
may provide the best solution. Hybrid systems combine a press-fit lens cap with a rear-mounted light pipe
(see Figure 7). With the addition of the gasket, this type of system can provide IP68 protection for very
reasonable costs.
Figure 7: The SGLC hybrid panel-mount design combines rear-mounted light pipe with a front-mounted press-fitted lens
and gaskets to achieve IP68 rating. [Source: Bivar]

1. The sealing ring has adhesive on both sides. To protect it, the ring is mounted on
a plastic backing with additional liner tape covering the adhesive on the opposite
side. Remove the liner tape and position the gasket over the panel hole, centering as
accurately as possible and pressing to get a good seal. Carefully peel off the plastic
backing.
2. Press lens through panel hole from front side. The flexible tabs at the distal end will
compress, then spring out once they pass through to lock the lens in place (see
Figure 8). Give the adhesive a few seconds to set.
3. Insert the light pipe into the lens cap from the rear side; the flexible tabs will move out
of the way and the crush ribs inside will ensure a friction fit.
CAUTION: To maintain IP rating, the panel thickness must meet datasheet specifications
to within tolerances.
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Figure 8: The SGLC uses a combination of front-side gasket and flexible locking tabs to compress the seal for an IP68 rating.
[Source: Bivar]
Figure 9: The combination of a sealing ring, locking washer, and hex nut provide high resistance to shock and vibration to
give the RHD an IP67 rating. [Source: Bivar]
Procedure for IP67 rated version with mechanical assist

For applications with high shock and vibration, industrial-grade mounting hardware
provides a more robust installation (see Figure 9).
1. Thread gasket over the lens until it is flush against flange (Note: with some products,
this may come preinstalled).
2. Insert lens cap through panel hole, pressing firmly until gasket is seated against the
metal.
3. From the rear side, slide the locking washer over the shaft of the lens cap, pushing it
up to the rear face of the panel.
4. Slide the nut over the shaft, with the flat face of the nut oriented toward the washer.
Tighten until it is finger tight against the washer.
5. Using a torque wrench, tighten the nut up to 6-7 in-oz.
6. From the rear side, insert the light pipe into the lens cap. The crush ribs will maintain a
friction fit.
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Board-mounting
Board-mount light pipes are physically attached to the PCB. Board-mounting requires an adapter that
connects to the board to enclose the LED. The board-end of the light pipe is then inserted into the adapter,
where it is held in place by crush ribs.
Board-mounting is an option for rigid light pipes but it is a requirement for flexible light pipes, to control
their compliance. All of the front-mount and hybrid approaches described for panel-mount light pipes can
be applied to board-mount light pipes. Flexible, board-mounted light pipes are available with integrated
lenses that provide IP67 ratings when properly front-mounted; flexible light pipes can also be used in a
hybrid mounting configuration for IP54 performance (see Figure 10). The difference is just that instead of
hovering over the LED and PCB, the distal end of the light pipe is pressed into the adapter, which controls
spacing. The contact with the panel can add extra stability, and even ingress protection, but the primary
connection is to the board.
Board-mount light pipes are good for systems exposed to high levels of shock and vibration. Assuming the
mounting holes have been properly positioned and machined to tolerance, the adapter ensures that the
light pipe is centered over the LED. It also maintains a specified spacing between the LED and the end face
of the light pipe, courtesy of an inner flange (see Figure 11). Finally, adapters prevent light bleed. Adapters
are available on the market designed to snap over rows of LEDs, speeding assembly and preventing light
bleed.
Figure 10: Flexible light pipes are available with a variety of mounting options, including front-mounted versions that offer
vibration protection IP67 ratings (the SMFLP, left) and hybrid versions with front-mounted lens caps and rear mounted light
pipes (the SZ, right). [Source: Bivar]
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There are two types of adapters: press-fit and soldered. The installation considerations are slightly
different for each.
Press-fit
Press-fit adapters incorporate prongs at the base that snap into predrilled holes in the board. The
prongs may be smooth or split. Split-prong designs deform upon insertion to provide extra stability.
Figure 11: A press-fit adapter features prongs that are pressed through predrilled holes in the PCB. They are quick to install
and provide extra stability. A flange in the interior (right) limits the insertion depth of the light pipe, protecting the LED
below. [Source: Bivar]
Procedure for press-fit-mounted adapters

1. Attach adapter to circuit board.
2. Install front-mount panel-mount lens cap, if required.
3. Insert indication end of light pipe into panel lens or panel aperture.
4. Insert board-end of light pipe into adapter, pressing until light pipe is firmly seated.
Crush ribs ensure friction fit.
CAUTION:
• Pins are plastic and can be damaged with rough handling.
• Because split prongs are deformable, installation is only good for one try – deformation
compromises any additional attempts.
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Solder on
Solder-on board-mount adapters are based on SMD LEDs. The LED is installed in an LED mount
during board assembly, then the adapter is attached to the assembly. In some cases, solder-on
board-mount adapters may be available with an integrated SMD LED to simplify installation. The
LED contacts project out from under the adapter, making it easy to solder in place (see Figure 12).
Procedure for solder-mounted adapters

1. Attach LED mount to the circuit board.
2. Insert LED into mount prior to reflow soldering step of PCB assembly.
3. During light-pipe assembly, snap the light-pipe adapter over the LED assembly (or buy
an all-in-one unit like Bivar’s SMTV that just needs to be soldered on during light-pipe
installation).
4. If light pipe is to be front mounted, perform that step first, then insert board-end of
light pipe into adapter, pressing until light pipe is firmly seated. Crush ribs ensure
friction fit.
5. If light pipe is to be rear mounted, insert board end of light pipe into adapter, then
insert indication end of light pipe into panel lens or panel aperture.
Figure 12: A solder-on adapter consists of the LED mount, the LED, and an adapter that snaps on over-the-top (left). The
leads for the LED project from the adapter for soldering (right). [Source: Bivar]
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Tips for success

Light pipes are straightforward to install. They can be very effective, providing technicians apply
best practices. To ensure optimal performance and minimize scrap:
• Develop detailed procedures.
• Make sure assembly technicians understand the importance of doing things correctly.
• Machine all parts to me datasheet specifications to within tolerances.
• Don’t rush.
• Position any part being inserted into a hole or aperture perpendicular to the surface.
• Remember, crush ribs are designed for a single use – once deformed, they no longer provide
tight fits.
• Consider integrated modules – there are solder-on board-mount adapters with integrated SMD
LEDs. Bivar is also developing a modular light-pipe system suitable for an array of LEDs
(see figure).
Conclusion
Light pipes can improve designs and enhance performance for indication, functional illumination,
backlighting, and even general illumination. Light pipes are fast and easy to install and don’t require
specialized tooling. It’s essential to use best practices, however. Success begins with accurate
specifications and proper dimensioning of parts. Pay attention to tolerances – the dimensions and
spacings of holes in the panel and on the board for board-mount adapters must be within tolerance.
For certain IP-rated assemblies, accurate panel thickness is a must. Crush ribs are only good for
one try – once deformed, they need to be replaced if insertion was unsuccessful. Probably the
single most important step is to educate assembly technicians – establish procedures based on best
practices and make sure they understand what they’re doing and how it will affect the performance
of the finished device.
Bivar has spent decades supporting customers in light-pipe design and installation. Let us help you
optimize the design and assembly of your next product. Contact us at…
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Guide To Installing LEDs and Light Pipes

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Guide To Installing LEDs and Light Pipes

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WHITEPAPER

Guide to Installing LEDs

It’s important to remember that light pipe performance is only as effective as

Light pipe types

General installation process

Front mounting options

IP-rated front-side panel mounts

Procedure for IP54 rated version

Procedure for IP67 rated version

Hybrid system – front-mount lens and rear-mount light pipe

Procedure for IP68 rated version

Procedure for IP67 rated version with mechanical assist

Procedure for press-fit-mounted adapters

Procedure for solder-mounted adapters

Tips for success

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