Backlight Module Recess Integrates Circuit Layer and Light Source
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Solution Overview
Problem
The conventional backlight module fabrication process is complex and costly due to the need for LEDs to be pre-welded onto a circuit board before being secured into the light source accommodating space.
Innovation Solution
A backlight module design where a light guide plate incorporates a recess for direct integration of a circuit layer, allowing light sources to be embedded and electrically connected without a circuit board, simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are pre-welded onto a circuit board before being secured into the light source accommodating space, then reliable electrical connection is achieved, but the fabrication process becomes complex and costly
Solution Approach 1:
The patent merges the circuit board and light source mounting functions into a single integrated structure. The circuit board includes a light source accommodating space with a recess that directly receives and secures the LED, eliminating the need for separate welding and mounting steps. This integration reduces fabrication complexity while maintaining reliable electrical connection through the circuit board's conductive traces.
Solution Approach 2:
The patent extracts the welding step from the fabrication process by designing a mechanical insertion system. The LED is directly inserted into the recess and secured with a fixing structure, removing the need for thermal welding operations. This extraction simplifies the manufacturing process while ensuring stable electrical connection through the integrated circuit board design.
2Reliability
If LEDs are pre-welded onto a circuit board, then stable electrical connection is achieved, but fabrication cost increases
Solution Approach 1:
The circuit board integrates multiple functions: electrical connection, mechanical support, and light source positioning. The recess structure combines the mounting cavity and electrical contact elements into a single integrated feature, reducing the number of components and assembly steps, thereby lowering fabrication cost while maintaining connection stability.
Solution Approach 2:
The circuit board's recess structure is designed to automatically position and secure the LED upon insertion. The fixing structure within the recess provides self-aligning and self-securing features that eliminate the need for additional welding or complex assembly operations, reducing manufacturing cost while ensuring stable electrical connection.
3Reliability
If a circuit board is used to mount LEDs, then electrical connection is achieved, but the number of components increases
Solution Approach 1:
The patent merges the circuit board with the light source mounting structure. The circuit board includes an integrated light source accommodating space with recesses that directly receive the LEDs, combining what would traditionally be separate components (circuit board, mounting bracket, securing elements) into a single integrated unit, thereby reducing the total number of components.
Solution Approach 2:
The circuit board is designed with multi-functionality: it provides electrical connection through conductive traces, mechanical support through the recess structure, and positioning through the integrated geometry. This universal design eliminates the need for separate specialized components for each function, reducing overall device complexity.
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 design simplifies the fabrication process and reduces costs by eliminating the need for pre-welding LEDs onto a circuit board, while ensuring efficient light emission and transmission through the light guide plate.
Implementation Method 1
the light emitted by the LED or the light source comes out uniformly from the surface of the light guide plate
Data Source
AI summary
A backlight module including a light guide plate, a circuit layer and at least one light source. The light guide plate includes a first surface, a second surface parallel and opposite to the first surface, and a recess disposed at a side edge of the light guide plate and including a third surface parallel to the first surface and the second surface. The circuit layer is integrated with the third surface. The at least one light source is disposed on the third surface to be embedded in the recess and electrically connected to the circuit layer.