Backlight Module With Integrated Conductive and Reflective Layers

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Solution Overview

Problem

Conventional backlight module assembly is prone to human error, leading to inaccurate placement of components and reduced optical luminance, resulting in yellowish light, gaps between light sources, and uneven brightness in display panels, which negatively impact display quality and thickness.

Innovation Solution

A backlight module design featuring an optical assembly with a base film, a conductive layer, and a reflective layer, where the reflective layer is integrated with the conductive layer to eliminate manual assembly and reduce thickness, using a plurality of light units electrically connected to the conductive layer, and a light guide plate positioned on the reflective layer, facilitating automated assembly and improved alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual assembly with tape is used to secure components, then components can be assembled, but assembly accuracy is poor and optical luminance is reduced

Engineering Contradiction:

Improvecomponent placement accuracyVSAvoidoptical luminance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The reflective layer and conductive layer are merged into a single integrated structure formed by printing the conductive layer pattern directly onto the reflective layer. This eliminates the need for separate assembly steps and tape, ensuring precise alignment and consistent optical performance without manual placement errors.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical assembly process using tape and manual placement is replaced by a printing process where the conductive layer is deposited directly onto the reflective layer. This substitution of mechanical assembly with a deposition process achieves superior precision and eliminates gaps between components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If tape is used to secure components, then components can be fixed in position, but the module thickness increases

Engineering Contradiction:

Improvecomponent fixationVSAvoidmodule thickness

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The reflective layer and conductive layer are combined into a single integrated structure, eliminating the need for separate fixation layers such as tape. This merging reduces the overall module thickness while maintaining secure component positioning through the integrated layer structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tape component is completely removed from the assembly process. Instead of using tape to secure components, the conductive layer is directly printed onto the reflective layer, extracting the unnecessary thickness-contributing element while maintaining fixation functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If manual assembly is used, then components can be assembled, but human error causes inaccurate placement and optical defects

Engineering Contradiction:

Improveassembly processVSAvoidcomponent alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Manual mechanical assembly is replaced with an automated printing process where the conductive layer pattern is directly deposited onto the reflective layer. This substitution eliminates human error in placement and alignment, achieving consistent precision across all modules.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The conductive layer pattern is prepared and printed onto the reflective layer in advance during the manufacturing process, before final assembly. This preliminary action ensures precise positioning is built into the structure itself, eliminating the need for subsequent manual alignment operations.

Inventive Principle:

Principle #10Preliminary action

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 solution enhances display quality by reducing human error, ensuring consistent light distribution, and achieving a thinner design by integrating the reflective and conductive layers, thus eliminating the need for manual assembly and tape, which can cause optical defects.

Implementation Method 1

a first reflective layer (13). The first reflective layer includes a first part (A) and a second part (B). The first part (A) is connected to the second part (B). The plurality of first light units (2) are disposed on the first part (A) and extend through the first part (A) to be electrically connected to the first conductive layer (12). The light guide plate (3) is disposed on the second part (B).

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS10690840B2Backlight module that has a reduced thickness comprising an optical assembly and display device comprising the same

Publication Date: 2020.06.23 INNOLUX CORP

AI summary

A backlight module includes an optical assembly, a plurality of first light units, and a light guide plate. The optical assembly includes a base film, a first conductive layer, and a first reflective layer. The first conductive layer is disposed on the base film, and the first reflective layer is disposed on the first conductive layer. The first reflective layer includes a first part and a second part. The first part is connected to the second part. The plurality of first light units are disposed on the first part and extend through the first part to be electrically connected to the first conductive layer. The light guide plate is disposed on the second part.