Threadlike Gap Filling for LED Module Edge Reflection
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Solution Overview
Problem
Existing methods for addressing irregular light reflection at gaps in LED module assemblies, such as using liquid resin or adhesive tape, suffer from issues like dripping, sagging, poor handleability, and limited adhesion, leading to inadequate coverage and increased production steps.
Innovation Solution
A gap-filling method involving a threadlike adhesive body is inserted into the gap to contact inner surfaces and edges, ensuring adhesion strength and reducing irregular light reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a liquid or gel-state resin material is applied to the gap between substrates, then the gap can be filled to reduce irregular light reflection, but the material is likely to drip or sag and this increases the number of production steps
Solution Approach 1:
The invention changes the physical state parameter of the adhesive material from liquid/gel to a solid threadlike form. This parameter change allows the adhesive to maintain its shape during application, preventing dripping and sagging, while still effectively filling the gap to eliminate irregular light reflection. The threadlike form enables direct insertion into the gap without requiring additional containment or application steps.
Solution Approach 2:
The invention extracts the harmful liquid/gel state properties (dripping, sagging) from the adhesive material and retains only the beneficial gap-filling and light-absorbing properties. By using a threadlike solid adhesive, the material achieves gap filling capability without the detrimental fluid characteristics that cause production complexity.
2Object-affected harmful factors
If adhesive tape is used to cover the gap between substrates, then irregular light reflection can be prevented, but the tape is prone to become twisted and has poor handleability requiring considerably larger number of steps
Solution Approach 1:
The invention changes the geometric form parameter from a flat tape structure to a threadlike three-dimensional form. This parameter change eliminates the twisting problem inherent in flat tapes and improves handleability. The threadlike form is inherently more flexible and easier to manipulate, allowing straightforward insertion into the gap without the handling difficulties associated with narrow adhesive tapes.
3Area of stationary object
If narrow adhesive tape is used to cover the gap while avoiding LED chips, then the gap can be covered, but the tape is prone to become twisted and has poor handleability
Solution Approach 1:
The invention changes the cross-sectional shape parameter from a flat narrow tape to a threadlike cylindrical form. This parameter change allows the adhesive to be inserted directly into the gap without requiring it to be narrow and flat. The threadlike form maintains flexibility and ease of handling while achieving effective gap coverage, eliminating the twisting issues that plague narrow flat tapes.
4Area of stationary object
If adhesive tape is applied to minute portions near edges of substrates, then the gap can be covered, but it is difficult to ensure an adhesion area and hence adhesion strength
Solution Approach 1:
The invention changes the application method parameter from surface application of narrow tape to insertion of threadlike adhesive into the gap. This parameter change allows the adhesive to be positioned precisely within the gap where it can achieve maximum contact with the substrate edges. The threadlike form ensures consistent adhesion area and strength by maintaining proper positioning within the gap, preventing the adhesion problems associated with narrow surface-applied tapes.
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 method effectively inhibits adverse effects from gap edges, enhancing appearance attractiveness by minimizing light reflection and improving adhesion without the drawbacks of previous methods.
Implementation Method 1
a threadlike adhesive body which has been inserted into the gap to fill the gap along thereof, wherein the threadlike adhesive body is in contact with at least some of inner surfaces of the gap and with edges of the gap
Data Source
AI summary
The present invention provides a gap-filling method whereby a structure having a gap can be appropriately inhibited from being adversely affected by edges of the gap. The present invention relates to a gap-filling method including filling a gap of a structure having the gap therein by inserting a threadlike adhesive body into and along the gap, wherein the threadlike adhesive body is inserted into the gap so as to come into contact with at least some of inner surfaces of the gap and with edges of the gap.