Backlight Module Light Source Substrate Blocks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process of conventional light sources for LCD backlights is complex and time-consuming due to the need for independent production and mounting of substrates and LEDs, with a complicated structure that includes bases and pins.
Innovation Solution
A light source with a simplified structure where LEDs are directly formed on a substrate with trapezoidal blocks and reflective layers, eliminating the need for bases and pins, and using a sealant with fluorescent powder to enhance light utilization, and a frame with step or wedge-shaped corners to engage the light source, allowing for efficient light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional light sources use independent substrates and LEDs with bases and pins, then the structure is stable and reliable, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges the substrate and LED components into an integrated structure where the LED is directly mounted on the substrate without separate bases and pins. The substrate serves dual functions as both the mounting platform and the structural support, eliminating the need for separate base components and reducing assembly steps while maintaining structural integrity.
Solution Approach 2:
The patent extracts and eliminates unnecessary components (bases and pins) from the conventional LED assembly. By removing these intermediate components, the design achieves direct mounting of LEDs on the substrate, simplifying the manufacturing process and reducing assembly complexity while maintaining reliable electrical and mechanical connections.
2Reliability
If conventional light sources include bases and pins for LED mounting, then the structure is stable, but the bulk and complexity of the light source increase
Solution Approach 1:
The substrate is designed to integrate multiple functions: it serves as the mounting surface for LEDs, provides structural support, and enables electrical connections. This merging of functions eliminates the need for separate base components and pins, reducing the overall volume and complexity of the light source assembly while maintaining mounting stability.
3Reliability
If conventional light sources use complicated soldering processes for mounting LEDs, then reliable electrical connections are achieved, but the manufacturing time increases
Solution Approach 1:
The substrate is pre-designed with integrated electrical connection structures and mounting features during the substrate fabrication process. This preliminary preparation eliminates the need for complex soldering operations during final assembly, as the electrical connections are already established in the substrate structure itself, thereby improving manufacturing efficiency while maintaining connection reliability.
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 simplifies the manufacturing process, reduces the bulk and complexity of the light source, and enhances light utilization efficiency by eliminating unnecessary components and optimizing the structure for better light distribution in LCD backlights.
Implementation Method 1
using a sealant with fluorescent powder to enhance light utilization
Implementation Method 2
The light guide panel transforms linear light to planar light
Data Source
AI summary
An exemplary backlight module includes a light source, a light guide panel, and a frame. The light source includes a substrate, blocks disposed on the substrate and spaced from each other, and light emitting diodes (LEDs) each including a first electrode, a second electrode, a chip and a bonding wire. The first and second electrodes are arranged on the substrate between two blocks, and are electrically connected to each other via the chip and the bonding wire. The light guide panel transforms linear light to planar light. The frame receives the light source. Each of two adjacent corners of the frame are step-shaped or wedge-shaped, with two ends of the light source correspondingly cut into step or wedge shapes to engage the frame.