Backlight Unit Light Source Separation Prevention
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Solution Overview
Problem
Direct type backlight units in LCD devices suffer from combination defects where light sources are easily separated from grips during assembly, leading to decreased productivity due to human error and improper fastening.
Innovation Solution
Incorporating protrusions on support sides that engage with light source grips to prevent separation, ensuring secure attachment and minimizing defects by forming a united shape with the support sides and drive PCBs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light sources are inserted into grips during assembly, then the backlight unit can be constructed, but the light sources are easily separated from the grips during assembly and feeding processes
Solution Approach 1:
The support side includes a protrusion that extends in advance during the assembly process to prevent the light source from separating from the grip. This preliminary protective structure is built into the support side before assembly begins, ensuring continuous secure attachment throughout the assembly and feeding processes.
Solution Approach 2:
The protrusion on the support side acts as an intermediary element between the light source and the grip. This intermediate structure provides additional mechanical engagement that prevents separation, serving as a mediator that reinforces the connection without requiring the light source to be directly fastened to the grip.
2Ease of operation
If light sources are fastened to grips by worker insertion, then the backlight unit can be assembled, but combination defects occur due to human error and careless mistakes
Solution Approach 1:
The protrusion on the support side provides self-aligning and self-securing functionality during assembly. The structural design automatically prevents misalignment and separation without requiring precise manual intervention, allowing the assembly process to be self-correcting and reducing the impact of human error.
Solution Approach 2:
The protrusion is pre-positioned on the support side to automatically engage with the light source during insertion. This preliminary positioning ensures that even if a worker makes a mistake during assembly, the protrusion will correct the alignment and prevent improper fastening, thereby improving combination precision.
3Device complexity
If simple grip structures are used, then the device complexity is reduced, but the light sources can be easily separated during feeding and combining processes
Solution Approach 1:
The support side is segmented into functional components: the main support structure and the protrusion element. This segmentation allows the protrusion to be added as a separate functional feature that enhances retention without significantly complicating the overall grip structure. The protrusion can be integrated into the support side manufacturing process without requiring separate complex assembly steps.
Data Source
AI summary
A backlight unit adapted to prevent a combination defect is disclosed.The backlight unit includes: a plurality of light sources arranged in fixed intervals; first and second light source printed-circuit-boards configured to apply driving signals to the plurality of light sources; a plurality of grips disposed on the first and second light source printed-circuit-boards and engaged with both ends of the light sources; and at least two support sides disposed on both ends of the light sources and configured to each include a protrusion which is united with the support side and is configured to prevent a separation of the light sources.