Folded Backlight Module Back Plate to Block Dust and Light Leakage
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Solution Overview
Problem
Conventional backlight modules suffer from dust penetration and light leakage due to holes in the back plate, which cause defects and reduced lighting efficiency.
Innovation Solution
A back plate design featuring an inner part, a bottom part, an outer part, a folded part, and a fastener, where the fastener is disposed on the outer part to secure the upper frame without holes, and the inner surface is made flat to prevent dust and light leakage, with the fastener formed by mechanical stamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hole is punched on the back plate to couple the upper frame, then the upper frame can be fixed on the back plate, but dust can penetrate through the hole causing bright/dark spot defects and vibration test failure
Solution Approach 1:
The invention extracts the harmful function of the hole (dust penetration path) while retaining its useful function (coupling structure). The hole is transformed into a folded part that extends outward to form a hook, eliminating the through-hole that allows dust entry while maintaining the coupling capability between back plate and upper frame
Solution Approach 2:
The invention transitions from a two-dimensional hole (flat surface penetration) to a three-dimensional folded structure (extending outward to form hook). This dimensional change allows the coupling structure to engage with the upper frame from the side rather than through a through-hole, blocking dust penetration paths while maintaining mechanical coupling
2Ease of manufacture
If a hole is punched on the back plate for light source mounting, then the light source can be installed, but light leaks through the hole decreasing lighting efficiency
Solution Approach 1:
The invention extracts the harmful light leakage function from the hole while preserving the light source mounting capability. The folded part creates a recessed area that accommodates the light source without requiring a through-hole, thereby preventing light from escaping through the back plate while maintaining easy light source installation
3Ease of manufacture
If a conventional punching process is used to create the hook, then the hook can be formed for coupling, but holes remain that allow dust penetration
Solution Approach 1:
The invention segments the back plate structure into distinct functional zones: the folded part forms the coupling hook, while the surrounding flat surface remains intact as a dust barrier. This segmentation allows the hook to perform coupling function without creating a continuous through-hole path for dust penetration
Solution Approach 2:
The folded part is formed as a preliminary structure during back plate manufacturing, creating the coupling hook before assembly. This preliminary formation ensures the hook structure is already in place to prevent dust entry, eliminating the need for subsequent hole-punching operations that would compromise dust protection
Data Source
AI summary
A back plate includes an inner part, a bottom part, an outer part, a folded part and a fastener. The bottom part is connected to the inner part for providing a container space. The outer part is opposite the inner part. The folded part is connected with the outer part and the inner part. The fastener is disposed on the outer part. A method for manufacturing the back plate is also disclosed herein.