Integrated Light Guide Circuit Structure for Backlight Modules
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Solution Overview
Problem
The conventional backlight module fabrication process is complex and costly due to the need for pre-welding LEDs onto a circuit board, which complicates the assembly and increases production expenses.
Innovation Solution
A light guide structure with integrated circuit layers and a recessed design that allows direct embedding and electrical connection of light sources, sharing the same material as the base, simplifies the assembly process and reduces costs by eliminating the need for pre-welding LEDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are pre-welded onto a circuit board to form an LED array, then the light source can be electrically connected, but the fabrication process becomes complex and costs increase
Solution Approach 1:
The patent merges the light guide plate and circuit board into a single integrated structure. The circuit layer is directly formed on the light guide plate, eliminating the need for separate LED welding onto a circuit board. This integration reduces fabrication complexity while maintaining electrical connection reliability through direct mounting of LEDs onto the integrated structure.
Solution Approach 2:
The light guide plate serves multiple functions: it guides light distribution and simultaneously acts as the circuit board substrate. The circuit layer integrated on the light guide plate performs both optical and electrical functions, reducing the number of separate components needed and simplifying the overall fabrication process.
2Adaptability or versatility
If multiple separate components (circuit board, LEDs, light guide plate) are used, then functional requirements are met, but assembly complexity and fabrication cost increase
Solution Approach 1:
The patent combines the light guide plate and circuit board into one integrated component, reducing the total number of parts from multiple separate components to a unified structure. This merger maintains all necessary optical and electrical functions while significantly reducing assembly steps and fabrication costs.
Solution Approach 2:
The integrated light guide plate-circuit board structure performs multiple functions simultaneously: light guidance, light distribution, and electrical circuit support. This multi-functionality eliminates the need for separate dedicated circuit boards and reduces component count, thereby lowering manufacturing costs.
3Adaptability or versatility
If conventional separate component assembly is used, then manufacturing flexibility is maintained, but production efficiency decreases
Solution Approach 1:
The integration of the light guide plate and circuit board into a single structure enables more efficient manufacturing processes. The unified structure can be produced as one piece through injection molding or other suitable processes, reducing assembly time and increasing production efficiency while still allowing design flexibility through the integrated circuit layer configuration.
Data Source
AI summary
A backlight module including a light source module and a light guide structure is provided. The light source module includes a base, at least one light source and a first circuit layer. The base includes a carrying surface. The at least one light source is mounted on the carrying surface. The first circuit layer is integrated with the carrying surface and electrically connected to the light source. The light guide plate includes an engaging surface and at least one recess. The engaging surface is engaged with the light source module. The recess is disposed at the engaging surface for receiving the light source, wherein a material of the light guide plate and a material of the base are the same. The second circuit layer is integrated with the engaging surface, and electrically connected to the first circuit layer.