Backlight Module Plastic Frame 3D Printing Thermal Expansion
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Solution Overview
Problem
In liquid crystal display technology, the thermal expansion of components within the backlight module's optical cavity leads to deformation, causing a wavy pattern that affects the display due to the narrow interval between components and the panel, especially when double-sided adhesive is inserted during assembly.
Innovation Solution
A backlight module is designed with a substrate, a plastic frame formed through 3D printing directly on the substrate's edge, creating a housing space, where a light guide plate and film set are stacked, and a rectangular tape is used to connect the plastic frame and film set without double-sided adhesive, allowing for thermal expansion and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If double-sided adhesive is used to attach the plastic frame to the substrate, then the assembly is securely fixed, but the adhesive is easily inserted into the optical cavity and elevates the light guide plate and film components, reducing the interval between components and the panel
Solution Approach 1:
The patent removes the double-sided adhesive from the assembly process entirely. Instead of using adhesive to attach the plastic frame to the substrate, the design relies on the plastic frame being formed directly on the substrate through 3D printing, creating an integrated structure that eliminates the need for separate attachment materials and prevents adhesive intrusion into the optical cavity.
Solution Approach 2:
The plastic frame and substrate are merged into a single integrated component through direct 3D printing on the substrate edge. This consolidation eliminates the interface between separate parts where adhesive would be applied, thereby preventing adhesive contamination of the optical cavity while maintaining structural integrity.
2Length of stationary object
If the interval between optical cavity components and the panel is reduced to minimize module thickness, then the backlight module is more compact, but thermal expansion of the film cannot be released, causing deformation to gather toward the center and form wavy patterns
Solution Approach 1:
The patent incorporates a rectangular tape and stepped surface design that creates pre-established expansion space within the optical cavity. This cushioning structure is built into the design before assembly, allowing the film to expand toward these designated areas during thermal expansion rather than forcing deformation into the center, thereby preventing wavy patterns while maintaining compact dimensions.
Solution Approach 2:
The patent introduces non-uniform spacing through the stepped surface recess and rectangular tape configuration, creating localized expansion zones within the optical cavity. This local quality variation allows different regions to serve different functions: some areas maintain tight spacing for compactness while others provide expansion buffer zones to accommodate thermal effects.
3Ease of manufacture
If 3D printing is used to form the plastic frame directly on the substrate, then the manufacturing process is simplified and assembly tolerances are reduced, but the plastic frame requires direct adhesion to the substrate which traditionally requires double-sided adhesive
Solution Approach 1:
The plastic frame is designed to be self-attached to the substrate through the 3D printing process itself. The printing process creates direct adhesion between the plastic frame and substrate without requiring separate adhesive materials or complex attachment mechanisms. The frame essentially attaches itself during the manufacturing process, simplifying both production and assembly.
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 solution prevents the elevation of light guide and film components, maintaining sufficient space for thermal expansion, thus avoiding the formation of wave patterns that could distort the liquid crystal display panel's image.
Implementation Method 1
the plastic frame being formed directly on the edge of the substrate through 3D printing
Implementation Method 2
If the optical cavity components are thermal expansion, the components can not expand to the surrounding to release the deformation
Data Source
AI summary
The present disclosure discloses a backlight module and the manufacturing method thereof. The backlight module comprises a substrate, a plastic frame, a light guide plate, and a film set. The plastic frame is formed on the substrate through printing, which forms a housing space together with the substrate. The light guide plate and the film set are sequentially stacked in the housing space. The backlight module according to the present disclosure will not affect the display of the liquid crystal display panel during thermal expansion.