Custom Size Small Backlight Module

1. Needs Integration and Solution Design: Customers provide specific customization requirements, including size, thickness, luminous area, optical parameters (brightness, color temperature, uniformity), power consumption requirements, installation method, application scenarios, and environmental adaptability requirements. The R&D team conducts a feasibility analysis of the needs, combining optical design principles and manufacturing processes to develop a customized product design solution, including structural design, light source selection, and diaphragm matching. Design drawings and sample solutions are generated and confirmed with the customer before proceeding to the next stage.

2. Core Component Customization and Procurement: Based on the confirmed design scheme, core components are custom-produced or procured, including a custom-sized light guide plate (made of high-transmittance acrylic material, processed with laser engraving and other techniques to create dots or microstructures), diffusion film, reflective film, and LED strips matching optical requirements (LED quantity and packaging method can be customized). All components undergo rigorous screening to ensure that indicators such as transmittance, reflectance, and luminous stability meet standards. Specifically, the light guide plate transmittance must be ≥92%, and the reflective film reflectance must be ≥98%.

3. Precision Assembly and Bonding: In a cleanroom, components are assembled according to the design drawings. First, the reflective film is attached to the inner wall of the back panel, then the light guide plate is installed, and its position is adjusted to ensure precise alignment. Subsequently, the diffusion film, brightness enhancement film, and other optical films are bonded sequentially, using a vacuum pressing process to ensure a tight, bubble-free bond to avoid affecting the optical effect. Next, the LED strips and driver components are installed, and the circuit is soldered to ensure stable circuit conduction and no poor contact issues. Assembly precision is controlled throughout the process to avoid compatibility problems caused by dimensional deviations. 4. Optical Debugging and Calibration: After assembly, the module undergoes optical performance debugging. Parameters such as brightness, color temperature, and uniformity are tested using professional equipment. Precise calibration is performed according to customer needs, adjusting drive parameters to fine-tune luminous efficacy, eliminating issues like light spots and light leakage, and ensuring optical performance meets customized standards. Simultaneously, dimming functionality and flicker are tested to ensure flicker-free and smooth dimming, meeting the luminous efficacy requirements of different scenarios.

5. Quality Inspection and Aging Test: Modules that pass debugging undergo comprehensive quality inspection, including appearance inspection (no scratches, damage, or deformation), dimensional inspection (ensuring consistency with customized specifications, with errors controlled within ±0.01mm), circuit inspection (no short circuits or leakage), and environmental adaptability testing (stability testing under high and low temperatures and humidity). An aging test is then conducted, with the module continuously lit for over 72 hours to check for brightness decay (attenuation rate must be <3%), ensuring long-term stable operation without potential malfunctions. Unqualified products will be returned for re-debugging or scrapped.

6. Packaging and Delivery: Qualified Custom Size Small Backlight Modules will be packaged in anti-static and anti-collision packaging, clearly labeled with product customization parameters and batch information, along with relevant test reports and installation instructions. After packaging according to customer requirements, logistics will be arranged for delivery to ensure the product is undamaged during transportation. Follow-up technical support will be provided to assist customers in completing module installation and debugging.