Metal Base Circuit Board Light Reflection Aluminum Foil
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Solution Overview
Problem
Conventional printed circuit boards for LED backlight systems lack a built-in light reflection function, leading to increased production complexity and reliability issues due to ion migration risks from silver plating in high humidity/high temperature environments.
Innovation Solution
A metal base circuit board with a layered structure of a metal plate, insulating layer, and metallic foils, including copper and aluminum, which integrates a white film for light reflection, eliminating the need for external light reflecting sheets and reducing ion migration risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If silver plating is applied to circuit portions to increase light reflectivity, then light reflection capability is improved, but reliability deteriorates due to ion migration in high humidity/high temperature environments
Solution Approach 1:
The patent replaces expensive silver plating with a cost-effective aluminum foil layer that provides sufficient light reflection without the reliability issues of silver. The aluminum foil serves as a disposable-like component in the circuit board structure, offering adequate functionality at lower cost and higher reliability.
Solution Approach 2:
The patent changes the material parameter from silver to aluminum for the reflective layer. This parameter change maintains the light reflection function while improving reliability by eliminating the ion migration problem associated with silver in humid and hot environments.
2Illumination intensity
If light reflecting sheets are applied after mounting LED packages to enhance light usage, then light reflection capability is improved, but device complexity increases due to additional production steps
Solution Approach 1:
The patent merges the light reflection function with the circuit board structure itself by integrating aluminum foil into the circuit board layers. This consolidation eliminates the need for separate light reflecting sheets and reduces production steps while maintaining effective light reflection.
Solution Approach 2:
The circuit board is designed to perform multiple functions: electrical connection through copper patterns and light reflection through aluminum foil. This multi-functionality eliminates the need for separate dedicated light reflection components, simplifying the overall device structure and production process.
3Ease of manufacture
If conventional printed circuit boards are used without built-in light reflection function, then manufacturing simplicity is maintained, but light reflection capability is insufficient for effective LED backlight usage
Solution Approach 1:
The patent combines the conventional circuit board manufacturing process with the integration of aluminum foil for light reflection. The aluminum foil is incorporated during the circuit board fabrication process, maintaining manufacturing simplicity while adding the necessary light reflection capability for effective LED backlight performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a compact, reliable, and efficient light reflection capability, enhancing the brightness and longevity of LED backlights while simplifying the manufacturing process by integrating light reflection within the circuit board.
Implementation Method 1
an aluminum layer is layered over part or all of said copper foil
Data Source
Figure 1~4
Figure 5~7
AI summary
Provided is a metal base circuit board having a new function of a light reflection in addition to the conventional printed circuit board function for mounting electronic parts. The metal base circuit board has a circuit arranged on a metal plate via an insulation layer. A white film is arranged at least one the insulation layer.