LED Light Source Module Support Structure for Precise Alignment
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Solution Overview
Problem
The alignment and utilization efficiency of LEDs in light source modules are compromised due to inclination and partial light coverage during surface mounting, leading to reduced light utilization efficiency.
Innovation Solution
An LED light source module design featuring a substrate with a protective layer and conductive terminals, along with an auxiliary structure that supports the light-emitting member, ensuring horizontal alignment and electrical connection, and includes a blocking member for stability, enhancing light coupling and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface mounting technology is used to affix LEDs to the printed circuit board, then electrical connection is achieved, but the LEDs become inclined and alignment precision deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the insulating layer at predetermined positions where LEDs will be mounted. These recesses are created before LED placement, establishing a predefined geometry that ensures proper alignment and prevents inclination during the mounting process. The recesses act as mechanical guides that constrain the LEDs to the correct orientation and position.
Solution Approach 2:
The insulating layer with recesses serves as an intermediary structure between the printed circuit board and the LEDs. This intermediate layer provides both electrical insulation and mechanical support, with the recesses acting as a mediator to transfer and maintain the precise alignment from the PCB to the LEDs, preventing direct contact that would cause inclination.
2Ease of manufacture
If LEDs are placed in openings of the protecting film, then mounting is simplified, but light alignment with the receiving surface deteriorates
Solution Approach 1:
The recesses are pre-formed in the insulating layer before LED mounting, establishing the correct height and orientation for light emission. This preliminary geometric preparation ensures that when LEDs are placed in the recesses, their light-emitting surfaces are automatically aligned with the receiving surface, eliminating the need for complex post-mounting adjustments.
Solution Approach 2:
The insulating layer is designed with local variations in height through the recesses, creating specific zones with different geometric properties. The recess areas provide localized support at precise heights, ensuring that only the LED mounting positions have the correct alignment characteristics, while other areas of the insulating layer maintain their original structure for electrical insulation.
3Strength
If reflection sheet or other objects are placed below the receiving surface, then structural support is provided, but light utilization efficiency deteriorates
Solution Approach 1:
The patent extracts the light-blocking function from the structural support role by separating these two functions into different components. The insulating layer with recesses provides structural support and alignment, while eliminating the need for reflection sheets below the receiving surface. This extraction removes the harmful light-blocking effect while preserving the necessary structural support through the recess geometry.
Solution Approach 2:
The insulating layer acts as an intermediary that provides structural support without blocking light. By positioning the recesses at the correct height and using the insulating material's mechanical properties, the structure gains necessary support while maintaining optical transparency, allowing light to pass through without being blocked by support structures.
Data Source
AI summary
An LED light source module includes a substrate; a protective layer disposed on the substrate and having at least one opening; a plurality of conductive terminals disposed in the at least one opening, a light-emitting member, a plurality of electrodes, and an auxiliary structure. The conductive terminals include a first conductive terminal and a second conductive terminal. The light-emitting member includes a bottom surface, a light-emitting surface connected to the bottom surface, a back surface opposite to the light-emitting surface, at least one lateral surface connecting the light-emitting surface and the bottom surface. The auxiliary structure includes a main support portion provided on the substrate to support the bottom surface of the light-emitting member, and the main support portion is located between the electrodes and extends at least from the back surface to the light-emitting surface of the light-emitting member.