Light Source Module Separator Structure for Dense LED Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional front matrix display lights for vehicles face issues with increased assembly tolerance requirements due to the denser arrangement of light-emitting diodes, leading to potential collisions between separators and diodes during assembly.
Innovation Solution
A light source module design featuring a separator with intersecting first ribs forming wide interval spaces and optional second ribs, along with pads and channels, creates clearance spaces to accommodate light-emitting elements without interference in all three axes, ensuring precise assembly and improved partition dimming performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the quantity of light-emitting diodes is increased to meet higher visual perception demands, then the resolution and image precision are improved, but the spacing between diodes is significantly reduced, resulting in more stringent assembly tolerance requirements and increased likelihood of collision between separator and diodes
Solution Approach 1:
The separator is designed with a stepped structure featuring different height levels, creating vertical clearance spaces between the separator and light-emitting diodes. This three-dimensional approach allows the separator to maintain its light-blocking function while providing sufficient spacing for assembly tolerance, effectively resolving the conflict between high density arrangement and assembly precision requirements.
Solution Approach 2:
The separator is divided into multiple regions with different heights, creating distinct clearance zones. This segmentation allows different portions of the separator to serve different functions: higher portions provide light blocking while lower portions create clearance spaces that accommodate the light-emitting diodes, preventing collision during assembly.
2Quantity of substance
If the spacing between light-emitting diodes is reduced to achieve denser arrangement, then the resolution is improved, but the assembly tolerance becomes more stringent and collision between separator and diodes becomes more likely
Solution Approach 1:
By introducing vertical clearance spaces through the stepped separator structure, the design enables dense horizontal arrangement of light-emitting diodes while maintaining reliable assembly. The clearance spaces provide a buffer zone that prevents collision between the separator and diodes during the assembly process, ensuring assembly reliability even at high densities.
3Measurement precision
If the separator is designed to closely fit the light-emitting diodes for precise partition control, then the partition dimming performance is improved, but the assembly tolerance requirements become more stringent
Solution Approach 1:
The separator is segmented into different height levels, with higher portions providing precise light blocking for partition control and lower portions creating clearance spaces. This segmentation allows the separator to achieve both precise partition dimming performance and relaxed assembly tolerance requirements simultaneously.
Solution Approach 2:
The stepped structure introduces vertical dimensionality to the separator design, creating clearance spaces that decouple the light-blocking function from the assembly tolerance requirement. This allows precise partition control to be maintained while providing sufficient clearance for reliable assembly.
Data Source
AI summary
A light source module is provided, including: a light board, including a substrate, and a plurality of light-emitting elements arranged at intervals on the substrate; and a separator, located above the substrate, and including a plurality of first ribs, where the plurality of first ribs is cross-connected to form a plurality of interval spaces, to accommodate the light-emitting elements, the first rib forming the interval space has an inner wall, a part of the inner wall in a direction closer to the substrate tapers in a direction far away from the interval space, the inner wall has a first distance farther away from the substrate in a Z-axis direction and has a second distance closer to the substrate, and a projection relationship between the second distance and the first distance onto an XY plane is that the second distance is greater than the first distance.