Backlight Frame Sheet Punching for Thin Profile
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Solution Overview
Problem
The challenge is to develop a backlight device that can accommodate the increasing demand for thinner and narrower frames in liquid crystal display devices, as the dimensions of traditional backlight units approach the structural limits of injection molding.
Innovation Solution
A backlight device is designed with a frame formed from a thin sheet material, featuring adhesive layers that are flush with the frame's surfaces, allowing for precise alignment and integration of a reflective sheet and optical members, and a light source, which are punched together to achieve a thinner and narrower profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If injection molding is used to manufacture the mold frame, then the frame can be produced with good structural integrity, but the frame dimensions approach the structural limit and cannot be made thinner or narrower
Solution Approach 1:
The patent replaces the injection molding process with a punching process using a sheet material. Instead of forming the frame through mechanical injection molding, the frame is created by punching holes in a sheet, allowing for much thinner and narrower dimensions that were previously unachievable with injection molding technology.
Solution Approach 2:
The patent employs a sheet material that can be punched into frame shapes, utilizing thin film technology to create frames with minimal thickness. This approach allows the frame to achieve dimensions below the structural limit of traditional injection molding while maintaining structural integrity through the punching process.
2Strength
If the adhesive layer width is greater than the frame width, then the adhesive provides sufficient bonding area, but the adhesive layer projects beyond the frame surface causing defects
Solution Approach 1:
The patent applies adhesive layers with different widths at different locations. The adhesive layer width is designed to match the frame width at specific regions, ensuring adequate bonding strength where needed while preventing projection beyond the frame surface in other regions. This localized variation in adhesive width resolves the contradiction between bonding strength and surface alignment.
3Manufacturing precision
If the frame and adhesive layer widths are equal, then the external surfaces are flush preventing projection issues, but the bonding area is reduced
Solution Approach 1:
The patent implements varying adhesive layer widths across different regions of the frame. In regions where flush alignment is critical, the adhesive width matches the frame width. In regions where bonding area is more important, the adhesive layer extends slightly beyond the frame edge. This spatial variation in adhesive dimensions allows the system to achieve both flush surfaces and adequate bonding strength simultaneously.
Data Source
AI summary
A backlight device is provided and includes a frame formed of a sheet material; a first adhesive layer provided on one surface of the frame; a reflective sheet attached to the frame with the first adhesive layer; an optical member disposed on the reflective sheet in the frame; and a light source disposed in the frame and configured to emit light to the optical member, wherein in at least a part of the frame, a width of the frame and a width of the first adhesive layer are equal to each other, and at least an internal surface of the frame and an internal surface of the first adhesive layer are flush with each other.