Backlight Module With Adhesive Layer And Protrusion
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Solution Overview
Problem
Conventional backlight modules for illuminated keyboards face issues with increased manufacturing costs due to irregular appearances and vulnerability to external forces and static electricity, particularly in flexible circuit board structures, and bulkiness when using rigid circuit boards.
Innovation Solution
A backlight module design incorporating a light-shielding sheet, light guide plate, reflective sheet, main circuit board, light-emitting unit, flexible circuit board, and electrical connector, where an adhesive layer protects the electrical connector and the reflective sheet's protrusion into the light guide plate's through hole retains the circuit boards horizontally, preventing light leakage and scratching, and the non-light-transmissive area of the light-shielding sheet ensures uniform light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible material circuit board structure is used, then flexibility and adaptability for complex circuit layouts are improved, but manufacturing cost increases due to irregular appearance
Solution Approach 1:
The circuit board is divided into two separate components: a rigid circuit board providing structural support and standard wiring, and a flexible circuit strip providing adaptability for complex layouts. This segmentation allows each component to be optimized independently, reducing overall manufacturing cost while maintaining flexibility.
Solution Approach 2:
The patent combines the rigid circuit board and flexible circuit strip into a unified circuit board assembly where the flexible strip is mounted on the rigid board. This merging integrates the advantages of both structures, achieving flexibility without the high cost of a completely flexible circuit board.
2Ease of manufacture
If a rigid material circuit board structure is used, then manufacturing cost is reduced, but the flexible circuit strip size increases significantly affecting overall volume
Solution Approach 1:
The flexible circuit strip is arranged in a folded or layered configuration on the rigid circuit board, utilizing three-dimensional space efficiently. This dimensional arrangement reduces the projected area and overall volume occupied by the circuit strip while maintaining its functional length and flexibility.
3Reliability
If welding is used to connect flexible circuit strip to circuit board, then electrical connection is achieved, but welding portions are exposed and vulnerable to external forces and static electricity
Solution Approach 1:
The patent applies a protective layer or coating over the welding portions before they are exposed to the environment. This protective layer acts as a cushion against external forces and static electricity, preventing damage to the vulnerable welding areas while maintaining electrical connectivity.
Solution Approach 2:
An intermediate protective structure or material is introduced between the welding portions and the external environment. This intermediary element shields the welding areas from harmful factors while allowing the electrical connection to function normally.
4Reliability
If the electrical connector protrudes through the light guide plate, then electrical connection is achieved, but light leakage and potential scratching of underlying components occur
Solution Approach 1:
The electrical connector is nested within a recess or cavity in the light guide plate, with the connector body positioned inside the through hole and only the necessary contact portions extending through. This nesting arrangement prevents light leakage around the connector while maintaining electrical connectivity.
Solution Approach 2:
An intermediate insulating or light-blocking material is placed around the electrical connector in the through hole to prevent light leakage. This intermediary material fills the gap between the connector and the light guide plate walls, blocking light paths while allowing electrical signals to pass through the connector.
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
The solution results in a lower profile, cost-effective, and reliable backlight module with improved light uniformity and protection against static electricity and mechanical stress, maintaining structural strength and antistatic properties.
Implementation Method 1
The adhesive layer is adhered between the reflective sheet and the main circuit board and covers the electrical connector
Implementation Method 2
The light-emitting unit is disposed on the main circuit board and passes through the opening to be accommodated in the slot hole. The light-emitting unit is configured to emit light toward the light guide plate
Implementation Method 3
The light guide plate is disposed under the light-shielding sheet and has a slot hole and a through hole. The light reaches the light exit area through the light guide plate
Implementation Method 4
The light guide plate is disposed under the light-shielding sheet and has a slot hole and a through hole. The light reaches the light exit area through the light guide plate
Implementation Method 5
The reflective sheet is disposed under the light guide plate and includes a protrusion and an opening
Data Source
AI summary
A backlight module includes a light-shielding sheet, a light guide plate under the light-shielding sheet, a reflective sheet under the light guide plate, a main circuit board under the reflective sheet, a light-emitting unit on the main circuit board, a flexible circuit board under the reflective sheet, and an electrical connector electrically connected to the flexible circuit board and the main circuit board. A protrusion of the reflective sheet protrudes into a through hole of the light guide plate. The light-emitting unit passes through an opening of the reflective sheet to be accommodated in a slot hole of the light guide plate. The light-emitting unit is configured to emit light to reach a light exit area of the light-shielding sheet through the light guide plate. The electrical connector is aligned with the through hole or further protrudes into the through hole.