Modular LED Backlight PCB Mounting for Field-Cut Installations
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Solution Overview
Problem
Current backlight LED installations, such as lattice, curtain, and ladder mounting systems, are not easily modifiable in the field, limiting design flexibility and customization, as they are typically manufactured for specific installations and not easily adaptable or upgradable.
Innovation Solution
The use of printed circuit boards (PCBs) with perforated or scored break points allows for customizable lengths and configurations, combined with a system of rails, clips, and end caps, enabling modular design and easy installation on various surfaces, including vertical and curved surfaces, with redundant current paths for maintaining illumination even after modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional lattice, curtain, or ladder mounting systems are used, then the lighting installation is structurally stable, but the system cannot be easily modified or customized in the field
Solution Approach 1:
The PCB is divided into multiple segments with perforated or scored break points that allow the board to be easily separated into smaller sections during installation. This segmentation enables field customization and modification without requiring complex tools or procedures, directly resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The mounting system transitions from a fixed, pre-manufactured configuration to a dynamic, field-adjustable system. The PCB segments can be selectively broken or removed to adapt the lighting array to different installation requirements, providing flexibility while maintaining a simple overall structure.
2Adaptability or versatility
If PCBs are cut or trimmed to customize lengths, then field customization is enabled, but the circuit continuity may be disrupted
Solution Approach 1:
Parallel current paths are预先 (pre-established) in the PCB design before any cutting or trimming occurs. These redundant conductors are built into the board structure, ensuring that when the PCB is later customized to specific lengths by breaking at perforated lines, the electrical circuit remains continuous and functional without requiring additional wiring or modifications.
3Productivity
If modular clips and rails are used for easy assembly, then installation speed is improved, but the structural strength may be reduced
Solution Approach 1:
The mounting system merges multiple functions into integrated components: the clips simultaneously provide mechanical attachment to the rail, structural support for the PCB, and electrical connection pathways. This consolidation achieves rapid tool-free assembly while maintaining adequate structural strength through the combined design rather than separate components.
Data Source
AI summary
Rack-type backlight light emitting element (LEE) printed circuit boards (PCBs) with at least two layers to provide redundant current paths. This enables a PCB strip to be broken at designated perforations in the field in order to accommodate pipes or fixtures that require formation of a gap in the rack array. The entire length and width of an array can be sized in the field. A plurality of PCB arrays can be serially chained together with the system. A chain of PCB strips is snapped into clips, which in turn snap into rails that are fastened to a surface. The mounting system includes various types of clips, such as end clips, clips for different LEE patterns on the PCBs, and mounting clips to secure the rails to a surface.