Angled LED Lens Module for Compact Backlight Assembly
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Solution Overview
Problem
Conventional LED lighting devices for television backlighting are inefficient in assembly and require a larger overall size, with potential loose contacts between components.
Innovation Solution
A non-rectangular LED set mounted on a printed circuit board (PCB) with a lens defining a chamber, where the LED set and lens form non-zero angles with the PCB, eliminating the need for a separate loader and allowing for efficient assembly and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional LED lighting device with a loader and separate LED chip is used, then the assembly structure is stable, but the assembly process is inefficient and the overall size is large
Solution Approach 1:
The patent merges the LED chip, loader, and lens into a single integrated LED module. The LED chip is directly mounted on the PCB without a separate loader, and the lens is integrated with the LED chip structure, eliminating multiple assembly steps and reducing overall device complexity while improving assembly efficiency.
Solution Approach 2:
The LED module is designed to perform multiple functions within a single component structure. The integrated module serves as both the light source and the optical element, combining the functions of the LED chip, loader, and lens into one universal component that simplifies the overall assembly.
2Volume of moving object
If a conventional LED lighting device with loader and separate components is used, then each component can be manufactured independently, but the overall device size is large
Solution Approach 1:
The patent combines multiple components into a single integrated LED module that is mounted directly on the PCB. This merging of the LED chip, loader, and lens into one compact unit significantly reduces the overall device volume while maintaining manufacturability through standardized integration processes.
Solution Approach 2:
The LED chip is nested within the lens structure, with the lens serving as the outer housing that contains and protects the LED chip. This nested arrangement minimizes the overall volume of the LED module while ensuring that each component maintains its functional integrity and can be manufactured using standard processes.
3Reliability
If a conventional LED lighting device with separate loader and LED chip is used, then component replacement is easier, but loose contacts may occur between components
Solution Approach 1:
The patent integrates the LED chip and loader into a single mounted unit on the PCB, eliminating the separate connection interfaces between the loader and LED chip. This integration eliminates potential loose contacts at connection points while maintaining ease of repair by allowing the entire LED module to be replaced as a single unit.
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
Enhances assembly efficiency, reduces component size, and eliminates loose contacts, while enabling controlled light projection for various applications.
Implementation Method 1
a light-emitting surface (LES) 102c of the LED set 102 and the PCB 110 also have the non-zero angle θ therebetween
Implementation Method 2
a lens that defines a chamber and that is disposed to cover the LED set within the chamber
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A lighting module (100) includes a non-rectangular light-emitting diode, LED set (102) to be disposed on a printed circuit board, PCB (110); and a lens (104) that defines a chamber (104e) and that is disposed to cover the LED set (102) within the chamber (104e). A light projecting device (300) that includes a plurality of LED sets (102) and a plurality of lenses (104) is provided as well.