Assembly Jig Grooves for LED Module Alignment
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Solution Overview
Problem
Misalignment of LEDs in the LED module during assembly leads to suboptimal optical coupling efficiency between LEDs and the light guide plate, resulting in uneven backlighting and reduced optical quality in conventional backlight modules.
Innovation Solution
An assembly jig with vertically arranged LED mounted portions and grooves on a stripe body, where the grooves are spaced to securely hold the LEDs in place, ensuring consistent positioning and alignment during the injection molding process of the light guide plate, using materials like polycarbonate or polymethylmethacrylate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface-mount technology is used to place LEDs on LED mounted portions, then the LED module can be manufactured, but misalignment occurs among LEDs causing suboptimal optical coupling efficiency
Solution Approach 1:
The patent applies preliminary action by pre-forming groove structures on the stripe body before LED mounting. These grooves are designed to receive and precisely position the LED mounted portions, ensuring alignment is established before the actual LED placement occurs. This preliminary structural preparation eliminates misalignment issues that would otherwise occur during surface-mount technology processing.
2Ease of manufacture
If conventional rectangular light guide plate is used, then manufacturing is simple, but distances between LEDs and light guide plate are not all zero affecting optical coupling efficiency
Solution Approach 1:
The patent applies local quality by modifying specific regions of the light guide plate structure. Instead of using a conventional rectangular light guide plate with uniform geometry, the invention introduces localized groove structures at specific positions where LEDs will be mounted. These local modifications ensure that the distance between each LED and the light guide plate is precisely controlled (all zero), optimizing optical coupling efficiency while maintaining overall manufacturing simplicity.
3Productivity
If LEDs are arranged without precise alignment, then assembly is faster, but backlighting uniformity and optical quality deteriorate
Solution Approach 1:
The patent introduces groove structures as an intermediary element between the LEDs and the light guide plate. These grooves serve as a mediating structure that automatically positions and aligns LED mounted portions during assembly. The intermediary groove structure guides the LEDs into precise positions without requiring complex alignment procedures, thereby maintaining fast assembly speed while ensuring uniform backlighting and high optical quality.
Data Source
AI summary
The present invention discloses an assembly jig for assembling a LED module and a light guide plate, the LED module comprises a circuit board and LED mounted portions which are vertically arranged on the circuit board, and the assembly jig comprises a stripe body and a plurality of grooves with notches on the stripe body, wherein the grooves are spaced and disposed across at least two adjacent sides of the stripe body to contain and tightly contact with the non-mounting surface of the LED mounted portions opposite to the mounting surface. The present invention also discloses a backlight module and a method which is used for assembling a LED module and a light guide plate by ensuring the same distances between each of the LEDs to the light guide plate, furthermore to obtain relatively uniform backlighting and high optical taste of the backlight module.