Flexible Circuit Board Connection Structure for LED Panel Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current LED panel light manufacturing processes using wire bonding have low production efficiency, high manpower costs, complex soldering processes requiring skilled technicians, and difficulty in standardizing design for large-scale production.
Innovation Solution
A lighting device with a flexible circuit board connection structure, where light source boards are fixed to a backboard and connected via flexible circuit boards with soldering structures and pads, allowing for standardized and automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire bonding is used for connections, then electrical connection between light source boards is achieved, but production efficiency is low and manpower costs are high
Solution Approach 1:
The patent merges the circuit board function with the connection function by integrating light source boards directly onto the flexible circuit board. This eliminates the need for separate wire bonding processes and reduces the number of discrete components, thereby improving production efficiency and reducing manpower requirements while simplifying the manufacturing process.
Solution Approach 2:
The flexible circuit board serves multiple functions simultaneously: it acts as both the electrical circuit carrier and the mechanical connection structure for light source boards. This multi-functionality eliminates the need for separate connection components and processes, directly addressing the contradiction between production efficiency and manufacturing complexity.
2Ease of operation
If wire bonding with soldering process is used, then electrical connection is established, but the process requires highly skilled technicians and longer operation time
Solution Approach 1:
The patent extracts the complex soldering process from the manufacturing workflow by eliminating the need for separate soldering operations. The light source boards are directly mounted and connected to the flexible circuit board through simplified connection structures, removing the time-consuming and skill-intensive soldering step while maintaining electrical connection functionality.
Solution Approach 2:
The patent employs pre-fabricated connection structures and modular light source board designs that can be quickly assembled without requiring highly skilled technicians. The simplified connection mechanisms allow for faster assembly operations, reducing the time and skill level requirements compared to traditional wire bonding with soldering processes.
3Reliability
If complex soldering process is used, then electrical connection is achieved, but yield rate is reduced due to process complexity
Solution Approach 1:
The patent removes the complex soldering process entirely from the manufacturing workflow. By using direct mounting and simplified connection structures on the flexible circuit board, the design eliminates the source of yield losses associated with complex soldering operations, thereby improving the overall yield rate while maintaining connection reliability through alternative connection methods.
Solution Approach 2:
The patent replaces the mechanical soldering process with alternative connection methods such as direct mechanical mounting, snap-fits, or pre-assembled connection modules. This substitution eliminates the complexity and yield losses associated with soldering while maintaining reliable electrical connections, thus improving productivity and yield rate.
4Adaptability or versatility
If manual wire bonding is used, then electrical connection is established, but design standardization is difficult and large-scale production is hindered
Solution Approach 1:
The flexible circuit board serves as a universal platform that integrates both the circuit functionality and the mechanical connection structures for light source boards. This multi-functional design enables standardized assembly processes and facilitates automation, as the integrated structure eliminates the need for complex manual wire bonding operations and allows for consistent, repeatable manufacturing at scale.
Solution Approach 2:
The patent segments the lighting device into modular components with standardized interfaces on the flexible circuit board. The light source boards are designed as separate modules that can be independently manufactured and then assembled onto the standardized connection structures of the flexible circuit board, enabling design standardization and facilitating automation in large-scale production while maintaining design flexibility.
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 flexible circuit board connection structure significantly improves production efficiency, reduces manpower costs, simplifies the manufacturing process, and enables large-scale production while providing flexibility in design to meet various application needs.
Implementation Method 1
each of the light source boards includes a plurality of electrodes. The flexible circuit board includes a plurality of soldering structures corresponding respectively to the light source boards, and each of the soldering structures includes a plurality of soldering pads. The electrodes of each of the light source boards are respectively soldered to the soldering pads of the soldering structure corresponding thereto.
Data Source
AI summary
The present invention discloses a lighting device with a flexible circuit board connection structure, which includes a backboard, a plurality of light source board, and a flexible circuit board. The light source boards are fixed to one side of the backboard, and each of the light source boards includes a plurality of electrodes. The flexible circuit board includes a plurality of soldering structures corresponding respectively to the light source boards, and each of the soldering structures includes a plurality of soldering pads. The electrodes of each of the light source boards are respectively soldered to the pads of the soldering structure corresponding thereto.