Segmented Light Source Module for Backlight Assembly
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Solution Overview
Problem
Conventional processes for manufacturing light source modules with long lengths along their longitudinal axis are inefficient and costly, particularly for large-sized display devices, due to low accuracy and high manufacturing costs associated with conventional surface mounting processes.
Innovation Solution
The solution involves using a base substrate with a long length to extend multiple light source modules with shorter lengths, each equipped with light-emitting devices, connected via surface mounting technology, allowing for efficient and cost-effective production of high-intensity, high-efficiency light source modules and backlight assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional surface mounting processes are used for manufacturing light source modules with long lengths, then manufacturing capability is maintained, but manufacturing efficiency is low and costs are high
Solution Approach 1:
The patent divides the light source module manufacturing into segments: a base substrate with connectors and multiple separate second substrates with light-emitting devices. These segments are manufactured independently and then connected through connection members, allowing parallel production and avoiding the need for single high-precision long-substrate manufacturing processes.
Solution Approach 2:
The patent introduces connection members as intermediaries that electrically connect the first connection pads on the base substrate with the second connection pads on the second substrates. This intermediary component enables modular assembly and simplifies the overall manufacturing process by decoupling the electrical connection function from the substrate itself.
2Device complexity
If a single long substrate is used for the light source module, then electrical connection is simplified, but manufacturing precision requirements increase and costs rise
Solution Approach 1:
The substrate system is segmented into a base substrate and multiple second substrates. Each substrate has standard, manageable dimensions with standard connection pad layouts, eliminating the need for precision manufacturing of extremely long substrates while maintaining simplified electrical connection through the modular design.
Solution Approach 2:
Connection members serve as intermediaries that bridge the electrical connection between substrates. These connection members have standardized connection interfaces that match the connection pads on both substrates, allowing precise alignment through standardization rather than requiring precision in the substrates themselves.
3Productivity
If multiple second substrates are connected to the base substrate, then manufacturing efficiency increases, but device complexity increases
Solution Approach 1:
The module is segmented into standardized components (base substrate, second substrates, connection members) that can be manufactured independently using standard processes. This segmentation enables parallel manufacturing and assembly, improving productivity while the standardization of interfaces keeps the structural complexity manageable.
Solution Approach 2:
The base substrate and second substrates use universal connection pad designs and standardized mounting structures. This universality allows multiple second substrates to be connected to the base substrate using the same connection methodology, simplifying the overall structure despite the increased number of components.
Data Source
AI summary
A light source module according to some example embodiments includes a first substrate and a plurality of second substrates. The first substrate includes a plurality of connectors configured to at least receive a supply of electrical power and a plurality of first connection pads that are configured to be electrically connected to the plurality of connectors. The second substrates each include a plurality of mounting elements on an upper surface and a plurality of second connection pads on a lower surface of the second substrate and configured to be electrically connected to the plurality of mounting elements. Each mounting element may be connected to a separate light-emitting device. A plurality of connection members may electrically connect the first connection pads of the first substrate to the plurality of second connection pads of the plurality of second substrates.