Backlight Module Composite Frame Enhances Strength and Brightness

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Solution Overview

Problem

Conventional backlight modules for thinner electronic display devices face challenges in achieving stable integral strength due to uneven surfaces and material differences between the optical plate and frame body, leading to reduced brightness and insufficient structural strength.

Innovation Solution

The integration of a first material frame and a second material frame, where the second material frame is embedded within the first, with the second frame having higher strength, is used to enhance the structural integrity and brightness of the display panel, employing injection molding and overmolding processes to create a metallic or high-strength material frame with a plastic frame, and incorporating a reflector for improved brightness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a single material frame is used to integrate the optical plate and frame body, then the manufacturing process is simple, but the integral strength is insufficient and unstable

Engineering Contradiction:

Improveintegral strengthVSAvoidframe structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs a composite frame structure consisting of a plastic frame body and an embedded metallic frame. The metallic frame provides high strength and stability, while the plastic frame body ensures even surface coverage and integration with the optical plate. This composite approach resolves the contradiction by combining materials with complementary properties to achieve both high integral strength and structural stability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The metallic frame is embedded within the plastic frame body, creating a nested structure where the high-strength metallic framework is contained within the outer plastic housing. This nesting arrangement allows the inner metallic frame to provide structural reinforcement without compromising the outer appearance or integration with the optical plate, thereby achieving enhanced strength while maintaining manufacturing simplicity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If the optical plate and frame body are made of different materials, then material selection flexibility is improved, but the integral strength becomes unstable

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidintegral strength stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent utilizes a composite material system where a plastic frame body is combined with an embedded metallic frame. The plastic material provides flexibility in design and integration with the optical plate, while the metallic embedded frame ensures stable and reliable integral strength. This composite approach allows different materials to be used together while maintaining stability through proper material selection and structural design.

Inventive Principle:

Principle #40Composite materials

3Illumination intensity

If the lateral sides of the optical plate are uneven and not provided with a reflector, then the manufacturing process is simple, but the brightness of the display panel decreases

Engineering Contradiction:

ImprovebrightnessVSAvoidoptical plate structure complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent merges the reflector function with the frame structure by integrating a reflector into the metallic frame assembly. This combination allows the frame to serve dual purposes: providing structural support and enhancing the brightness of the display panel through light reflection. The integrated design avoids adding separate reflector components, thereby maintaining manufacturing simplicity while improving brightness.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach results in a backlight module with enhanced strength and brightness, suitable for thinner display panels, while also reducing assembly time and costs, and can be adapted for various electronic products.

Implementation Method 1

manufactured by the injection molding process which integrates the optical plate, the first material frame and the second material frame into an integrated structure

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

manufactured by the overmolding process to integrate the frame body and the optical plate by means of a metallic frame

Methodology Applied

Scientific EffectOvermolding:

Data Source

PatentUS8162527B2Backlight module and the method for manufacturing the same

Publication Date: 2012.04.24 AU OPTRONICS CORP

AI summary

A backlight module and a manufacture method thereof are provided. The backlight module includes a frame body and an optical plate. The frame body includes a first material frame and a second material frame, and the second material frame is embedded in the first material frame and the strength of the second material frame is higher than that of the first material frame. The first material frame enwraps part of the second material frame to form at least one connection part, and the optical plate is disposed in the frame body and is connected with at least one connection part.