Fire Resistant LED Module Metal Mask Design
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Solution Overview
Problem
Existing LED display screens lack a simple and effective method to achieve both optical performance and fire resistance, as conventional rubber or plastic masks do not provide sufficient flame retardancy.
Innovation Solution
A fire-resistant LED module using a metal mask with flame-retardant glue and a sub-black insulating surface layer, where the metal mask is etched to form precise mounting grooves for LED lamp beads and coated with flame-retardant glue for attachment to a PCB, utilizing non-combustible metals like aluminum, steel, or stainless steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a rubber or plastic mask is used to cover the PCB and eliminate reflection and chromatic aberration, then optical performance is improved, but fire resistant performance deteriorates
Solution Approach 1:
The patent changes the material parameter of the mask from combustible rubber or plastic to non-combustible metal (such as aluminum alloy), thereby maintaining optical performance while achieving fire resistance. The metal mask can still eliminate reflection and chromatic aberration while providing inherent fire resistant properties without requiring additional flame retardant coatings.
Solution Approach 2:
The patent employs a composite structure combining metal mask with flame-retardant glue coating. The metal provides structural integrity and fire resistance, while the flame-retardant glue coating enhances the fire resistant properties and provides adhesion. This composite approach ensures both optical performance and superior fire resistant performance.
2Reliability
If a coating containing flame retardant is applied on the mask to improve fire resistant performance, then fire resistant performance is improved, but device complexity and production process complexity increase
Solution Approach 1:
The patent changes the fundamental material parameter from combustible to non-combustible metal, which inherently provides fire resistance without requiring complex flame retardant coatings. This simplifies the mask structure while maintaining or improving fire resistant performance.
Solution Approach 2:
The patent extracts the fire resistant function from the complex coating system and integrates it into the base metal material selection. By choosing inherently fire resistant metal materials, the need for additional flame retardant layers is reduced or eliminated, simplifying the overall structure.
3Reliability
If a metal mask is used to provide fire resistance, then fire resistant performance is improved, but manufacturing precision and mounting groove accuracy may deteriorate
Solution Approach 1:
The patent replaces traditional mechanical cutting or drilling methods for creating mounting grooves with laser processing technology. Laser processing enables precise formation of mounting grooves on metal masks with high accuracy, eliminating the manufacturing precision issues associated with conventional mechanical methods on metal materials.
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 provides a cost-effective, simple production process with enhanced fire resistance and improved optical performance by reducing light reflection and chromatic aberration, while ensuring the module's safety in fire-prone situations.
Implementation Method 1
A layer of flame-retardant glue is coated on one side, facing the PCB, of the metal mask, the metal mask is pasted with the PCB through the flame-retardant glue
Implementation Method 2
A sub-black insulating surface layer is disposed on the metal mask... the sub-black insulating surface layer... absorbs ambient light and further improves contrast
Implementation Method 3
performing an etching process on the metal mask according to arrangement of the plurality of the LED lamp beads on the PCB, and forming the mounting grooves
Data Source
AI summary
The present disclosure provides a fire resistant LED module, including a metal mask and a printed circuit board (PCB). A layer of flame-retardant glue is coated on one side, facing the PCB, of the metal mask, and the metal mask is pasted with the PCB through the flame-retardant glue. A sub-black insulating surface layer is disposed on the metal mask. The present disclosure further provides a manufacturing method of the fire resistant LED module, including following steps: processing surfaces of the metal mask after etching to form the sub-black insulating surface layer; coating the flame-retardant glue on one surface of the metal mask facing the PCB; and covering the metal mask on the PCB through the flame-retardant glue. The sub-black insulating surface layer is formed through processing the surfaces of the metal mask 1.