LED Light Source Module With Auxiliary Structure For Alignment
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Solution Overview
Problem
Conventional LED light source modules face issues with alignment precision and light utilization efficiency due to the inclination of LEDs during surface mounting, leading to misalignment with receiving surfaces and partial light coverage by opening walls.
Innovation Solution
An LED light source module design featuring a substrate with a protective layer, conductive terminals, and an auxiliary structure between them, which supports the light-emitting member to maintain horizontal alignment and prevent light coverage, enhancing light utilization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If surface mounting technology is used to affix LEDs to the printed circuit board, then the manufacturing process is simplified and productivity is improved, but the alignment precision deteriorates because the LEDs easily become inclined during insertion
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the protective layer at precise positions before mounting the LEDs. These recesses are created during the PCB fabrication process, establishing the correct alignment positions in advance. When LEDs are later inserted, they naturally settle into these pre-prepared recesses, ensuring accurate alignment without requiring complex adjustment during assembly.
Solution Approach 2:
The patent introduces an intermediary structure - the recesses formed in the protective layer - that mediates between the mounting process and the LED positioning. These recesses act as physical guides that constrain the LEDs to correct positions, preventing inclination during the surface mounting process while maintaining manufacturing simplicity.
2Ease of manufacture
If LEDs are inserted into openings of the protecting film, then the manufacturing process is simplified, but the light utilization efficiency deteriorates due to light misalignment and partial coverage by opening walls
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the protective layer that precisely match the LED positions and orientations. These recesses are created during PCB fabrication before LED assembly. When LEDs are inserted, they settle into these pre-prepared recesses, ensuring their light-emitting surfaces are correctly oriented toward the light guiding member, thereby preventing light misalignment and coverage by opening walls.
Solution Approach 2:
The recesses in the protective layer serve as an intermediary structure that mediates between the simple insertion process and the precise light alignment requirement. By providing physical guidance and positioning, these recesses ensure that LEDs are correctly oriented without complicating the assembly process, thus maintaining ease of manufacture while improving light utilization efficiency.
Data Source
AI summary
An LED light source module is provided, including a substrate, a protective layer, a first conductive terminal, a second conductive terminal, at least one auxiliary structure, and a light-emitting member. The protective layer is disposed on the substrate and has an opening. The first conductive terminal, the second conductive terminal, and the auxiliary structure are disposed on the substrate and accommodated in the opening, wherein the auxiliary structure is disposed between the first conductive terminal and the second conductive terminal. The light-emitting member has a first electrode and a second electrode, respectively electrically connected to the first conductive terminal and the second conductive terminal. The auxiliary structure is disposed between the light-emitting member and the substrate. A method for manufacturing the aforementioned LED light source module is also provided.