Backlight Module Abutting Structures LED Alignment
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Solution Overview
Problem
Conventional backlight modules experience light leakage and uneven brightness due to the thickness of adhesives used to attach the light guide plate to the circuit board, leading to misalignment of light-emitting diodes and the light guide plate, resulting in bright bands and reduced optical quality.
Innovation Solution
The use of abutting structures on the flexible circuit board to deform and adjust the position of light-emitting elements relative to the light guide plate, compensating for the thickness of adhesives and improving the coupling effect between the light guide plate and light-emitting elements, thereby reducing light leakage and enhancing uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesives are used to fix the light guide plate on the circuit board, then the light guide plate can be attached, but the thickness of the adhesives causes misalignment between light-emitting diodes and the light guide plate, resulting in light leakage and uneven brightness
Solution Approach 1:
The adhesive layer is segmented into multiple discrete adhesive points rather than a continuous layer. This segmentation allows the light guide plate to be positioned at multiple contact points, enabling compensation for thickness variations and achieving better alignment between LEDs and the light guide plate while maintaining easy attachment.
Solution Approach 2:
The solution introduces a vertical dimension adjustment by designing the light guide plate with a curved or uneven bottom surface that corresponds to the adhesive distribution. This dimensional change allows the top surface of the light guide plate to be coplanar with the LEDs despite the presence of adhesive thickness, resolving the alignment issue.
2Strength
If the light guide plate is completely attached to the circuit board, then attachment strength is improved, but the light-emitting surface cannot be aligned with the central axis of the light incident surface, causing bright bands
Solution Approach 1:
The light guide plate is designed with different surface qualities at different locations. The bottom surface has localized contact areas that correspond to adhesive positions, while the top surface maintains a coplanar, uniform quality for consistent light emission. This local differentiation allows strong attachment at specific points while maintaining overall brightness uniformity.
3Manufacturing precision
If adhesive thickness is reduced to improve alignment, then alignment precision improves, but attachment reliability deteriorates
Solution Approach 1:
The adhesive system is segmented into multiple discrete points rather than a thin continuous layer. This segmentation allows each adhesive point to provide strong localized bonding while the overall thickness remains controlled, achieving both high attachment reliability and good alignment precision simultaneously.
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
This solution effectively reduces the risk of light leakage and bright lines, improving overall light uniformity and allowing for the design of ultra-thin display devices by aligning light-emitting elements with the light guide plate, thus enhancing the optical quality and reducing the device thickness.
Implementation Method 1
the flexible circuit board is deformed at the position of the abutting structures
Data Source
AI summary
A backlight module comprises an outer frame unit, a light guide plate arranged in the outer frame unit, a light-emitting unit, a plurality of adhesives for fixing the light-emitting unit on the light guide plate, and a plurality of abutting structures. The light-emitting unit includes a flexible circuit board and a plurality of light-emitting elements arranged on the flexible circuit board at intervals. Part of the flexible circuit board is deformed at a specific position by the abutting structures, and the position of the light-emitting elements relative to the light guide plate can be adjusted. Thereby, the light-emitting elements can be aligned with the light incident surface of the light guide plate, prevent light from leaking from the light emitting surface of the light guide plate close to the light-emitting elements, and reduce the generation of bright lines and improving the overall uniformity. The present invention also provides a display device including the backlight module.