Backlight Module Corner Keying for Fast, Error-Free Assembly
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Solution Overview
Problem
The challenge of quickly and efficiently tiling and assembling backlight modules during production in liquid crystal display apparatuses is not adequately addressed by existing technologies.
Innovation Solution
A backlight module design featuring a backplane with inner and side frames forming an accommodation space, a middle frame with a fixing portion and extension portions, and fool-proof structures at corners to ensure correct installation direction, along with snap-in structures for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional assembly methods are used for backlight modules, then assembly process is simple, but assembly speed is slow and production efficiency is low
Solution Approach 1:
The backlight module is divided into distinct components: backplane, middle frame, light source assembly, and optical film set. Each component is independently manufactured and then assembled through the snap-in structures, enabling parallel production and faster assembly speed while maintaining clear structural boundaries.
Solution Approach 2:
The snap-in structures are pre-formed on the backplane and middle frame during manufacturing. These pre-formed connection structures enable rapid assembly without requiring complex fastening operations during the assembly process, thereby improving production efficiency.
2Manufacturing precision
If traditional assembly methods are used for backlight modules, then assembly process is simple, but assembly accuracy is low and errors are frequent
Solution Approach 1:
Fool-proof structures are incorporated at specific corners of the backplane and middle frame, creating asymmetric features that provide visual cues for correct orientation. These asymmetric markers ensure that components are assembled in the correct direction, eliminating assembly errors without requiring complex alignment procedures.
Solution Approach 2:
The snap-in structures are designed to automatically guide and secure the middle frame to the backplane in the correct position. The structures self-align during assembly, ensuring high assembly accuracy without requiring additional alignment tools or complex adjustment procedures.
3Productivity
If snap-in structures are added to improve assembly efficiency, then assembly speed increases, but device complexity increases
Solution Approach 1:
The snap-in structures are integrated into the existing backplane and middle frame designs rather than being added as separate components. This merging approach enables rapid assembly while minimizing the increase in overall structural complexity, as the connection features are incorporated into the primary structural elements.
4Manufacturing precision
If fool-proof structures are added to ensure correct orientation, then assembly accuracy improves, but device complexity increases
Solution Approach 1:
Fool-proof structures are placed only at specific corner locations of the backplane and middle frame rather than being distributed throughout the entire structure. This localized approach provides sufficient orientation guidance for accurate assembly while minimizing the overall increase in structural complexity.
Data Source
AI summary
A backlight module includes a backplane, a light source, an optical film set and a middle frame. The backplane includes an inner bottom frame and inner side frames that constitute a first accommodation space. The inner bottom frame includes side surfaces. The inner side frames are respectively connected to the side surfaces. The light source and the optical film set are disposed in the first accommodation space. The middle frame includes a fixing portion surrounding and connected to the inner side frames. The backplane includes a plurality of inner corners defined by the inner side frames and the inner bottom frame, and the fixing portion includes outer corners corresponding to and matching with the inner corners. A fool-proof structure is disposed at least at an inner corner of the backplane and an outer corner of the middle frame.