Light Source Module Scanner Assembly for LED Optical Uniformity
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Solution Overview
Problem
The manufacturing of light source modules using LEDs faces challenges in achieving optical uniformity due to defects in coaxial precision between LEDs and lenses, leading to issues like the Mura phenomenon, which reduces product reliability and productivity.
Innovation Solution
A method involving the use of a light source module scanner assembly to inspect and capture images of LEDs and optical devices on substrates, allowing for the identification and correction of defects, thereby ensuring proper alignment and mounting, which enhances optical uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inspection of mounted lens and LED is implemented, then optical uniformity quality is improved, but process efficiency and productivity decrease
Solution Approach 1:
The patent performs inspection of lens-LED coaxial precision at an early stage in the manufacturing process, before final assembly completion. By capturing images and analyzing alignment status during the mounting process rather than after final assembly, the system enables early detection and correction of alignment issues, maintaining optical uniformity while avoiding rework that would reduce productivity
Solution Approach 2:
The patent replaces manual inspection methods with an automated optical inspection system that uses image capture devices and analysis algorithms to automatically detect coaxial precision defects. This automation eliminates time-consuming manual inspection while maintaining high detection accuracy, thereby improving both optical uniformity quality and manufacturing productivity
2Adaptability or versatility
If degree of integration of LEDs is decreased, then manufacturing flexibility is improved, but process efficiency and productivity reduce
Solution Approach 1:
The patent employs a movable scanner assembly that can dynamically adjust its position and scanning parameters to accommodate different LED integration configurations. The system can adapt to various substrate layouts and LED arrangements by changing scanning speed, image capture frequency, and analysis parameters, maintaining process efficiency across different manufacturing scenarios while providing the flexibility to handle varying integration degrees
Data Source
AI summary
Manufacturing a light source module may include mounting light emitting devices on substrates on an upper surface of a carrier, mounting optical devices to cover the light emitting devices, and inspecting the light emitting devices and the optical devices based on selectively capturing images thereof. Images may be captured based on controlling a light source module scanner assembly on the carrier. The substrates may extend in a first direction and may be spaced apart in a second direction. Controlling the light source module scanner assembly may include moving the light source module scanner assembly along a selected direction to position the light source module scanner assembly on at least one of the light emitting devices and the optical devices. The direction may be selected based on the quantity of substrates and the quantity of light emitting devices and optical devices on each of the substrates.