Flat Light Source Unit Molded Connection Cord Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flat light source units using tube type lamps, such as EEFL and CCFL, face issues with high power consumption and significant light variation with temperature, while LED-based units face challenges with unstable electrical connections due to detachment of connection cords during manufacturing, increasing manufacturing time and costs, and device size.
Innovation Solution
A flat light source unit with a printed circuit board (PCB) featuring a mold that encompasses the connection cord, providing a stable electrical connection and reducing the risk of detachment, and an optional slot socket and slot film for additional securement, using a silicon mold to adhere to the PCB and encompass the connection cord or slot socket, ensuring reliable connections and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shrink tube is used to encase the connection cord, then the electrical connection stability is improved, but the manufacturing process complexity and time increase
Solution Approach 1:
The invention extracts the essential function of the shrink tube (protecting and securing the connection cord) and implements it through a simplified direct attachment method where the connection cord is securely fastened to the PCB without requiring the complex shrink tube process, thereby maintaining reliability while reducing manufacturing complexity
Solution Approach 2:
The invention replaces the thermal-mechanical shrink tube system with a simpler mechanical attachment system, eliminating the need for heating, shrinking, and complex multi-step processes while achieving the same protective and securing functions
2Reliability
If a shrink tube is used to encase the connection cord, then the electrical connection stability is improved, but the manufacturing cost increases
Solution Approach 1:
The invention removes the shrink tube component and its associated manufacturing steps, reducing material costs and processing costs while maintaining the protective and securing functions through alternative simple attachment methods
Solution Approach 2:
The invention replaces the expensive shrink tube system with inexpensive alternative attachment methods that achieve the same functional outcome without requiring costly materials or complex processes
3Reliability
If a shrink tube is used to encase the connection cord, then the electrical connection stability is improved, but the device size increases
Solution Approach 1:
The invention extracts and removes the shrink tube component, eliminating the additional volume it would add to the device while maintaining the protective and securing functions through more space-efficient attachment methods
4Ease of operation
If the connection cord is inserted into a connection slot, then the ease of assembly is improved, but the reliability deteriorates due to easy detachment
Solution Approach 1:
The invention creates a dynamic connection system that combines the ease of slot insertion with the stability of secured attachment, allowing for simple assembly while preventing detachment through the integrated mold structure that locks the connection cord in place
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 stabilizes electrical connections, reduces manufacturing complexity and costs, and minimizes device size by preventing cord detachment and enhancing reliability, while maintaining efficient light emission in a plane for liquid crystal display devices.
Implementation Method 1
using a silicon mold to adhere to the PCB and encompass the connection cord
Data Source
AI summary
A flat light source unit includes a PCB on which at least one light emitting diode is mounted, a connection cord electrically connected to a conductive pattern on the PCB to supply a drive voltage to the at least one light emitting diode, and a mold formed on the printed circuit board to encompass a part of the connection cord.