Backlight Module Assembly to Suppress Reflective Sheet Bulging

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Solution Overview

Problem

Conventional backlight modules suffer from optical distortions due to thermal expansion of the reflective sheet, which bulges and can cause LED failures when fixed to a back plate with screws, leading to instability and reduced performance.

Innovation Solution

A backlight module design that incorporates a recess and post connecting structure between the reflective sheet and back plate, allowing for relative movement and generating a drag force to suppress bulging during thermal expansion, thereby maintaining optical quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the reflective sheet is fixed to the back plate with screws, then assembly is completed and structural connection is achieved, but the reflective sheet bulges upward due to thermal expansion, harming optical quality and causing LED failures

Engineering Contradiction:
Improvestructural connectionVSAvoidoptical quality
Core Design Contradiction:
Stability of the object's compositionVSReliability

Solution Approach 1:

The connecting structure transitions from a static rigid connection to a dynamic adaptive connection. The inclined guiding surface allows the post to move along a predetermined path during thermal expansion, enabling the structure to adapt to temperature changes while maintaining connection integrity and preventing bulging that would harm optical quality

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The connecting structure exploits thermal expansion parameter changes by designing the inclined guiding surface that converts the reflective sheet's thermal expansion into controlled movement along the slope. This transforms the harmful expansion into a useful mechanism that maintains contact between components while accommodating size changes, preventing LED failures and preserving optical quality

Inventive Principle:
Principle #35Parameter changes

2Stability of the object's composition

If the reflective sheet is constrained by the back plate with fixed screw distances, then structural stability is maintained, but the reflective sheet cannot expand freely, causing upward bulge and pushing LEDs

Engineering Contradiction:
Improvestructural stabilityVSAvoidupward bulge
Core Design Contradiction:
Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The connecting structure is specifically designed to accommodate thermal expansion of the reflective sheet. The inclined guiding surface provides a pathway that allows the reflective sheet to expand in the horizontal direction while the post moves along the slope, converting thermal expansion into beneficial movement that maintains structural stability and prevents upward bulge

Inventive Principle:
Principle #37Thermal expansion

Solution Approach 2:

The connecting structure introduces a dimensional transformation by using an inclined surface. The thermal expansion that would normally cause vertical bulging is redirected into horizontal movement along the inclined guiding surface, effectively converting a harmful three-dimensional deformation into a controlled two-dimensional movement that maintains optical quality

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 effectively suppresses reflective sheet bulging, ensuring stable light uniformity and improved reliability under severe thermal conditions, reducing assembly costs and labor, and enhancing the module's adaptability to high-temperature environments.

Implementation Method 1

the end portion of the post abuts and moves under guidance from the guiding surface, so a drag force is generated to pull the reflective sheet toward the back plate

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 2

the coefficient of thermal expansion of the reflective sheet is larger than that of the back plate, i.e. size increase of the reflective sheet is larger than that of the back plate when heated

Methodology Applied
Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12474608B2Backlight module and display device
Publication Date: 2025.11.18 RADIANT OPTO ELECTRONICS CORP
  • US12474608B2 patent drawing
  • US12474608B2 patent drawing
  • US12474608B2 patent drawing

AI summary

A backlight module has a back plate having a supporting surface, a reflective sheet, a light source board, and at least one connecting structure. The reflective sheet is arranged on the supporting surface of the back plate along an assembling direction. The light source board is disposed between the reflective sheet and the back plate. The at least one connecting structure has a recess and a post. The recess has an opening and a guiding surface connected to the opening and inclined along a guiding direction relative to the supporting surface. The post has an end portion configured to pass through the opening of the recess and hook the guiding surface. The back plate and the reflective sheet are mounted via the recess and the post. A display device is also provided.