Mini LED Backlight Protection Layout for Tighter Printing Tolerances
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Solution Overview
Problem
Existing backlight modules using Mini LEDs face challenges in manufacturing accuracy, leading to inadequate protection and reduced light efficiency due to larger manufacturing tolerances in transparent protective structures.
Innovation Solution
A backlight module design featuring a driving backplate with pads, Mini LEDs electrically connected to the pads, and transparent protection structures manufactured using steel mesh printing, which allows for precise adjustment of the protection structure's size and height to improve protection and light efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for transparent protection structures, then manufacturing process is simpler, but manufacturing precision deteriorates leading to larger tolerances
Solution Approach 1:
The patent introduces specific geometric parameter constraints for the transparent protection structure: the first distance (from geometric center of orthographic projection of transparent protection structure to geometric center of orthographic projection of light-emitting diode) is controlled to be within 50μm, while the second distance (length of orthographic projection of light-emitting diode) is 100-500μm, and the third distance (width of orthographic projection of light-emitting diode) equals the second distance. The ratio of first distance to second distance and first distance to third distance is controlled at 1:2 to 1:10. These parameter changes ensure manufacturing precision while maintaining practical manufacturability.
2Reliability
If transparent protection structures are provided closer to light-emitting diodes, then protection effect is enhanced, but manufacturing tolerance impact increases
Solution Approach 1:
The patent optimizes the distance parameter between transparent protection structures and light-emitting diodes. By controlling the first distance to be within 50μm (while maintaining a practical minimum distance for manufacturing), the patent achieves close proximity for enhanced protection while the specific ratio constraints (1:2 to 1:10) provide a tolerance buffer that reduces sensitivity to manufacturing variations.
Solution Approach 2:
The patent establishes precise geometric relationships and distance constraints during the design and manufacturing planning stage. By pre-defining the first distance, second distance, third distance, and their ratios, the patent prepares the manufacturing process with clear tolerance specifications, allowing for proactive quality control and reducing the impact of tolerances on the final protection effect.
3Illumination intensity
If Mini LEDs are used as backlight source, then brightness and contrast are improved, but manufacturing accuracy requirements increase leading to inadequate protection
Solution Approach 1:
The patent introduces a comprehensive set of geometric parameters and their constraints specifically tailored for Mini LED backlight modules. The first distance (≤50μm), second distance (100-500μm), third distance (=second distance), and their ratios (1:2 to 1:10) create a standardized design framework that accommodates the small size of Mini LEDs while ensuring adequate protection and maintaining manufacturing feasibility.
Solution Approach 2:
The patent segments the backlight module into distinct functional components with clearly defined geometric relationships: light-emitting diodes, transparent protection structures, and their spatial relationships defined by multiple distance parameters. This segmentation allows for independent optimization of each component while maintaining overall system precision through the defined parameter constraints.
Data Source
AI summary
A backlight module comprises a driving backplate, which comprises multiple pads; multiple light-emitting diodes, which are electrically connected to the pads; and multiple transparent protection structures, which are located on the sides of the multiple light-emitting diodes that are away from the driving backplate, wherein the transparent protection structures cover the light-emitting diodes, there is a first distance between the center of the orthographic projection of each transparent protection structure on the driving backplate and the center of the orthographic projection of each light-emitting diode on the driving backplate; and the length of the orthographic projection of each light-emitting diode on the driving backplate is a second distance, the width of the orthographic projection of each light-emitting diode on the driving backplate is a third distance, the ratio of the first distance to the second distance is less than or equal to 1:2-1:10.