Backlight Module Film Layer Hanging Gap Design
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Solution Overview
Problem
Ultra-large display modules (98 inches and 110 inches) face challenges due to their backlight modules' inability to adapt to the expansion of the film layer, limiting their market competitiveness.
Innovation Solution
A backlight module design featuring a back panel with hanging elements and a film layer with strategically placed hanging holes and gaps, allowing for expansion in both horizontal and vertical directions, and including a reflective and diffusion plate for improved light distribution and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the film layer is rigidly fixed to the back panel, then the structural stability is improved, but the thermal expansion of the film layer causes plate wrinkling and reduces reliability
Solution Approach 1:
The patent transforms the rigid fixed connection into a dynamic adjustable connection by introducing hanging elements with gaps that allow the film layer to move and expand thermally while remaining connected, resolving the contradiction between structural stability and thermal expansion accommodation
Solution Approach 2:
The patent changes the connection parameter from rigid fixed to flexible suspended with specific gap dimensions, allowing the film layer to expand thermally without causing wrinkles while maintaining overall structural integrity
2Adaptability or versatility
If the film layer is allowed to expand freely, then the thermal expansion is accommodated, but the structural support and positioning are insufficient
Solution Approach 1:
The patent segments the continuous film layer into sections separated by hanging elements, allowing each section to expand independently while the hanging elements provide discrete support points that maintain overall structural integrity
Solution Approach 2:
The hanging elements act as intermediaries between the back panel and the film layer, providing both support and allowing thermal expansion, thus mediating between the need for structural strength and thermal adaptability
3Manufacturing precision
If the hanging elements are positioned close to the film layer edges, then the positioning precision is improved, but the light distribution uniformity deteriorates due to shadow effects
Solution Approach 1:
The patent applies different gap distances at different locations of the hanging elements, with smaller gaps near edges for positioning precision and larger gaps in the center for light distribution, creating local quality variations that satisfy different functional requirements
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 design effectively accommodates the thermal expansion of the film layer, preventing defects like plate wrinkling and ensuring high reliability and compatibility in various orientations, thus enhancing the performance and durability of ultra-large display modules.
Implementation Method 1
the film layer is at a side away from the back panel, of the first middle frame... in each set of hanging hole and hanging element corresponding to each other on the first side, a first gap is provided between a sidewall away from the fourth side, of the hanging element and a sidewall away from the fourth side, of the hanging hole, and in a direction from the third side to the fourth side, the first gaps between the hanging holes and hanging elements corresponding to each other gradually increase in size
Data Source
AI summary
A backlight module and a display device, including a back panel, a first middle frame, and a film layer. The film layer includes a first side, a second side, a third side, a fourth side. Hanging holes are at edges of the film layer. Hanging elements corresponding to hanging holes are on the back panel. The hanging element is connected to the film layer via hanging hole. Among hanging holes and hanging elements on the first side, from the third side to the fourth side, first gaps between sidewalls of hanging elements away from the fourth side and sidewalls of hanging holes away from the fourth side increase; among hanging hole and hanging element on the third side, from the first side to the second side, a first gap between sidewall of hanging element away from the second side and sidewall of hanging hole away from the second side increases.