LED Module Aperture Layout for Precise Light-Emitting Positioning
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Solution Overview
Problem
Existing light-emitting diode (LED) modules in image output devices face challenges in maintaining accurate light-emitting positions due to deviations during the reflow process in surface-mount technology, affecting the resolution of photosensitive arrays.
Innovation Solution
A light-emitting module with a substrate and precisely controlled light-emitting elements, utilizing a light-shielding structure and light-emitting holes formed through photolithography and etching processes to accurately define the light-emitting position, ensuring accurate light emission and improved resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If surface-mount technology with reflow process is used to mount light-emitting elements on PCB, then mass production efficiency is improved, but light-emitting position accuracy deteriorates due to element deviation during reflow
Solution Approach 1:
The patent applies preliminary action by pre-defining the light-emitting position through a light-shielding structure with precisely positioned openings before the reflow process. The light-shielding structure is formed on the PCB substrate prior to mounting the light-emitting elements, establishing a fixed reference framework that prevents position deviation during subsequent reflow soldering operations.
Solution Approach 2:
The light-shielding structure serves as an intermediary element between the PCB substrate and the light-emitting elements. It mediates the position accuracy issue by providing a stable, pre-formed aperture pattern that constrains and defines the effective light-emitting position, decoupling the final position accuracy from the reflow process variations.
2Device complexity
If light-emitting elements are mounted directly on PCB without light-shielding structure, then device complexity is reduced, but light-emitting position control precision deteriorates
Solution Approach 1:
The patent applies segmentation by separating the position control function from the mounting structure. The light-shielding structure is divided into a PCB substrate layer and an aperture pattern layer, where the aperture pattern specifically handles position definition while the substrate provides mechanical support. This segmentation allows independent optimization of position precision without significantly increasing overall device complexity.
Data Source
AI summary
A light-emitting module is provided. The light-emitting module includes a substrate and n number of light-emitting elements disposed on the substrate. The n number of light-emitting elements have n−1 number of first intervals. The n−1 number of first intervals have a first standard deviation, wherein n is greater than or equal to 3. The light-emitting module further includes a light-shielding structure which is disposed on the n number of light-emitting elements and has n number of light-emitting holes. The n number of light-emitting holes correspond to the n number of light-emitting elements, respectively, and have n−1 number of second intervals. The n−1 number of second intervals have a second standard deviation, wherein the first standard deviation is greater than the second standard deviation.