Backlight Connector Clipping Mechanism for Assembly Efficiency

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional backlight structures have complex assembly and disassembly processes that require manual welding, leading to increased costs, labor, and reduced manufacturing efficiency.

Innovation Solution

A backlight structure design that uses a connector and electrically conductive elements to simplify the assembly process by replacing welding with electrical connections, allowing for easier assembly and disassembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual welding is used to connect power wire to tubular lamp, then electrical connection is achieved, but assembly complexity and labor cost increase

Engineering Contradiction:

Improveelectrical connectionVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical clipping system. The electrically conductive element with clipping structure mechanically engages with the tubular lamp to achieve electrical connection, eliminating the need for welding equipment and manual welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary electrically conductive element that serves as a mediator between the power wire and the tubular lamp. This element features a clipping structure that facilitates connection without direct welding, simplifying the assembly process while maintaining reliable electrical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If manual welding is used for assembly, then electrical connection is established, but manufacturing efficiency decreases

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the time-consuming welding process with a quick mechanical clipping action. The clipping structure allows for rapid connection and disconnection, significantly improving manufacturing efficiency and productivity while maintaining reliable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electrically conductive element is pre-formed with the clipping structure integrated into its design. This preliminary preparation eliminates the need for on-site welding operations, allowing for faster assembly and improving overall manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If connector passes through frame opening and circuit board through hole, then electrical connection is simplified, but structural precision requirements increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent employs asymmetric design in the clipping structure and engagement features of the connector. The one-way clipping mechanism allows easy insertion through the frame opening and circuit board through hole, while the asymmetric geometry ensures proper alignment and prevents misalignment issues.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

Instead of requiring precise pre-alignment of holes before insertion, the patent inverts the approach by using a clipping structure that self-aligns during insertion. The flexible or resilient clipping elements adapt to slight misalignments, making the assembly process more tolerant of manufacturing variations.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS8070313B2Backlight structure including clipping connectors

Publication Date: 2011.12.06 AU OPTRONICS CORP

AI summary

A backlight structure comprises a frame, a circuit board, and a connector. The frame has an opening. The circuit board is located below the frame and has a through hole, wherein the through hole aligns with the opening. The connector passes through the opening and the through hole, protrudes from a surface of the frame, and is electrically connected to the circuit board.