Backlight Module Rubber Frame Gap Spacer Design
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Solution Overview
Problem
Existing backlight modules face issues due to non-flat back plates causing local protrusions and foreign object retention, leading to picture defects like 'squeeze white' and 'point damage', which complicates defect identification and increases quality abnormalities during production and transportation.
Innovation Solution
A backlight module design featuring a concavely formed groove on the back plate with a spacer between the groove and the reflective sheet, forming a gap to prevent protrusions and foreign objects, and a rubber frame with a press portion to offset deformation, along with a pressure groove structure and roulettes on the reflective sheet for enhanced alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the back plate surface is made flat through machining, then the picture quality improves, but the machining complexity and cost increase
Solution Approach 1:
A buffer layer is introduced between the back plate and the reflective sheet to act as an intermediary element. This buffer layer compensates for the non-flatness of the back plate surface, allowing the use of simpler machining processes while maintaining the required optical quality by absorbing surface irregularities before they affect the light reflection.
2Object-affected harmful factors
If the back plate is made completely flat, then foreign object retention is reduced, but the manufacturing difficulty and time increase
Solution Approach 1:
The buffer layer serves as a mediator that prevents foreign objects from being trapped between the back plate and reflective sheet. By providing a compliant interface, it allows for faster assembly processes without requiring extremely tight tolerances or multiple inspection steps, thus maintaining productivity while reducing defect rates.
3Stability of the object's composition
If the light guide plate is pressed firmly against the back plate, then assembly stability improves, but picture defects increase due to contact force on protrusions
Solution Approach 1:
The buffer layer is positioned beforehand between the light guide plate and back plate to provide cushioning. This pre-positioned cushioning layer distributes the contact force evenly, preventing the concentration of stress on local protrusions that would otherwise cause picture defects like squeeze white, while still maintaining adequate assembly stability.
4Manufacturing precision
If foreign objects are completely removed during assembly, then picture quality improves, but the assembly time and inspection complexity increase
Solution Approach 1:
The buffer layer acts as a protective intermediary that tolerates the presence of minor foreign objects without allowing them to cause picture defects. This eliminates the need for extensive foreign object removal and inspection procedures, reducing assembly time and complexity while maintaining acceptable picture quality.
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 design effectively reduces quality defects and scrap rates by preventing protrusions and foreign object-induced issues, ensuring a smoother assembly and improved display performance.
Implementation Method 1
A top surface of the spacer facing towards the reflective sheet is closer to the reflective sheet than an inner surface of the back plate, so that a gap is formed between the reflective sheet and the back plate
Implementation Method 2
the rubber frame has a press portion that protrudes and extends towards the periphery of the reflective sheet, and an end of the press portion is pressed against the periphery of the reflective sheet
Implementation Method 3
the periphery of the reflective sheet is bent towards the back plate to form a pressure groove structure, and a notch of the pressure groove structure facing towards the press portion is pressed against a bottom of the pressure groove structure
Data Source
AI summary
The present disclosure provides a backlight module, and a display panel and a display having the same. The backlight module includes a back plate, a light guide plate, and a reflective sheet. The inner surface of a periphery of the back plate is concavely formed with a groove. The light guide plate is disposed on an inner surface of the back plate, and the reflective sheet is disposed on a bottom surface of the light guide plate facing towards the back plate. The backlight module further includes a spacer. The spacer is disposed between a bottom of the groove and the reflective sheet. A top surface of the spacer facing towards the reflective sheet is closer to the reflective sheet than the inner surface of the back plate, so that a gap is formed between the reflective sheet and the back plate.