Foldable Light Source Module for High Density LED Backlight
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Solution Overview
Problem
Conventional light source modules for LCDs face challenges in achieving high brightness due to the limited density of LEDs, as they must maintain a minimum distance to avoid short circuits and ensure secure adhesion, restricting the number of LEDs that can be used, especially in compact designs.
Innovation Solution
A foldable light source module is introduced, where two sets of LEDs on opposing substrates interlace, allowing for increased density by overlapping their positions, thereby accommodating more light sources within a fixed display area, and reducing the light mixing distance for enhanced brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are disposed on a substrate with sufficient pad size and minimum distance to avoid short circuits, then the reliability of LED connection is improved, but the density of LEDs on the substrate deteriorates
Solution Approach 1:
The patent transitions from a single-plane LED arrangement to a three-dimensional folded structure where LEDs are disposed on both the front surface and the folded-back substrate surface. This dimensional change allows LEDs to be positioned in multiple spatial layers, effectively increasing LED density without compromising the minimum distance requirements or pad size for reliable connections.
Solution Approach 2:
The folded substrate structure creates a nested arrangement where the substrate is folded back onto itself, allowing LEDs on the folded portion to be positioned within the spatial envelope of the original substrate area. This nesting effect increases the effective LED count within the same footprint while maintaining proper spacing and connection reliability.
2Illumination intensity
If the number of LEDs is increased to meet higher brightness requirements, then the illumination intensity is improved, but the device complexity increases
Solution Approach 1:
By utilizing the folded substrate configuration, the patent increases LED count and thus brightness without proportionally increasing device complexity. The folded structure efficiently packs more LEDs into the same footprint, and the interlaced arrangement with optical films creates a systematic, repeatable pattern that manages complexity through regularity rather than random complexity.
Solution Approach 2:
The patent combines multiple functional elements into an integrated folded structure where the substrate serves both as mechanical support and as the carrier for LEDs on multiple surfaces. The optical films are integrated between LED layers, merging light guiding, mixing, and extraction functions into a compact multi-layer assembly that achieves high brightness without linearly increasing overall complexity.
3Quantity of substance
If LEDs are disposed closer together to increase density, then the light mixing distance is shortened, but the risk of short circuit between solders increases
Solution Approach 1:
The folded substrate arrangement allows LEDs to be positioned close together in the planar footprint while maintaining adequate spacing in the three-dimensional structure. LEDs on the folded-back portion are spatially separated from LEDs on the original surface through the fold, enabling high density without compromising solder joint separation and short circuit prevention.
Solution Approach 2:
The interlaced arrangement creates an asymmetric pattern where LEDs are offset between the front surface and folded surface rather than being uniformly spaced on a single plane. This asymmetric positioning allows for optimized spacing that maintains solder joint integrity while achieving higher overall density through the folded configuration.
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 enhances the brightness of flat panel displays by increasing the density of light sources, allowing for more LEDs to be used while maintaining the same display area, and optimizes light utilization by reducing the gap between emitting elements.
Implementation Method 1
The first light sources and the second light sources are respectively driven in opposite directions. Hence, the lights from the first light sources and the second light sources are respectively reflected and mixed by a set of optical films disposed between the first substrate and the second substrate to thereby provide the backlight for the LCD.
Data Source
AI summary
A foldable light source module and a backlight module with the light source module are provided. The light source module includes a first substrate, first light sources, a second substrate, and second light sources. The first substrate has a first surface and a first connecting portion. The first light sources are arranged in a line and disposed on the first surface. A first gap is kept between the neighboring first light sources. The second substrate which has a second surface and a second connecting portion is disposed parallel to the first substrate, wherein the second surface faces the first surface, and the second connecting portion connects to the first connecting portion. The second light sources are arranged in a line and disposed on the second surface. A second gap is kept between the neighboring second light sources. At least a portion of the second light source extends into the corresponding first gap and, conversely, at least a portion of the first light source extends into the corresponding second gap.