Light Module Circuit Board Fixation via Through-Hole Bending

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Solution Overview

Problem

Conventional backlight modules for LCD devices face reliability issues due to damage of the flexible second circuit board during assembly, leading to faulty lighting and decreased product yield.

Innovation Solution

A light module design where the second circuit board is passed through openings in the first circuit board to form bending portions, allowing for fixation without adhesive tape, thereby minimizing damage and ensuring reliable electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the second circuit board is wound around the first circuit board to fix them together, then the fixation effect between the two circuit boards is improved, but the second circuit board may be damaged during the assembling process

Engineering Contradiction:

Improvefixation effectVSAvoidquality of electrical connection

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The second circuit board is divided into multiple portions: a first portion that extends from the rear surface of the first circuit board, a second portion that is folded back, and a third portion that extends forward. This segmentation allows each portion to serve different functions - providing fixation while avoiding damage during assembly, thereby resolving the contradiction between fixation effect and reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second circuit board transitions from a simple planar winding around the first circuit board to a three-dimensional configuration with multiple folded portions. By adding spatial dimensionality (frontward extension, folding back, and forward extension again), the design achieves both stable fixation and protection of the electrical connection quality during assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Stability of the object's composition

If adhesive tape is used to increase the fixation effect between the two circuit boards, then the fixation in horizontal and vertical directions is improved, but the complexity of the assembling process increases

Engineering Contradiction:

Improvefixation effectVSAvoidassembling process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The adhesive tape is completely removed from the design. Instead of using external fixation materials, the second circuit board itself is configured with folded portions that provide the necessary fixation effect. This extraction of the adhesive tape simplifies the assembling process while maintaining the required fixation stability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The second circuit board serves its own fixation function through its folded configuration. The first portion, second portion, and third portion work together to secure the circuit board assembly without requiring external adhesive tape, thereby reducing assembling process complexity while maintaining fixation effectiveness.

Inventive Principle:

Principle #25Self-service

3Reliability

If the second circuit board is wound around the first circuit board, then the electrical connection between external circuits and the light source is established, but the second circuit board is susceptible to damage from assembling actions or the light shade

Engineering Contradiction:

Improveelectrical connection qualityVSAvoiddamage from assembling actions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The second circuit board is pre-configured with a folded structure (first portion extending rearward, second portion folded back, third portion extending forward) before the final assembly. This preliminary configuration protects the electrical connection portions from damage during subsequent assembling actions or when the light shade is installed, while maintaining reliable electrical connectivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The folded portions of the second circuit board act as protective buffers that absorb or deflect potential damage from assembling actions or light shade installation. The multi-portion configuration provides inherent protection to the electrical connection areas before harmful factors can affect them.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS8734000B2Light module, composite circuit board device used therein, and assembling method thereof

Publication Date: 2014.05.27 AU OPTRONICS CORP

AI summary

A light module and an assembling method thereof are disclosed. The light module includes a first circuit board, a second circuit board, and a light source, wherein the first circuit board has a first opening and a second opening, and the second circuit board has a first bending portion. The light source is disposed on the first circuit board. The second circuit board passes through the first opening and the second opening of the first circuit board to form the first bending portion and the first circuit board and the second circuit board are fixed together to complete the light module assembling.