Composite Backlight Module Injection Molding Integration
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Solution Overview
Problem
Conventional LCD backlight modules have a high component count and complex assembly processes, leading to increased material costs and manufacturing difficulties, necessitating a reduction in components and simplification of the assembly procedure.
Innovation Solution
A composite backlight module integrating a bezel, cell, film, and light bar with a light guide portion and reflector, where the light bar includes LEDs or CCFLs, and the components are molded together using injection molding to reduce complexity and material usage, while maintaining mechanical integrity and optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional backlight modules use separate components (backcover, frame, light guide plate), then structural stability and optical quality are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the backcover, frame, and light guide plate into a single integrated backlight housing component. This merging reduces the total number of separate parts while maintaining the structural support function and optical quality through carefully designed integrated features including mounting positions and light guiding surfaces.
Solution Approach 2:
The integrated backlight housing serves multiple functions simultaneously: it provides structural support (frame function), protects internal components (backcover function), and guides light distribution (light guide plate function). This multi-functionality eliminates the need for separate dedicated components for each function.
2Ease of manufacture
If conventional backlight modules use multiple separate components, then assembly flexibility is improved, but manufacturing procedure complexity and time increase
Solution Approach 1:
By integrating multiple components into one molded piece, the patent eliminates multiple assembly steps required for separate components. The single integrated component can be produced through injection molding in one process, significantly improving manufacturing efficiency and reducing assembly time while maintaining the necessary flexibility for installation.
3Adaptability or versatility
If conventional backlight modules use separate components, then component replacement flexibility is improved, but material cost and assembly complexity increase
Solution Approach 1:
The patent reduces material cost by eliminating the need for multiple separate components and their associated joining materials (adhesives, fasteners). The integrated design uses a single material for the housing structure, reducing total material consumption and simplifying inventory management while maintaining adaptability through design features like mounting positions and light guiding surfaces.
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 simplifies the manufacturing process, reduces material costs, and decreases the number of components by integrating key elements into a single module, enhancing light distribution and luminance through uniform illumination.
Implementation Method 1
a light guide portion for guiding light emitted by the light bar toward a light exit surface of the composite backlight module
Implementation Method 2
a light guide portion for guiding light emitted by the light bar toward a light exit surface of the composite backlight module
Implementation Method 3
the reflector is disposed at the bottom and the periphery of the composite backlight module for reflecting light emitted toward the bottom of the composite backlight module to enhance the utility rate of the light
Implementation Method 4
the film uniformizes a light and supplies a uniformly distributed light source to the cell
Data Source
AI summary
The present invention discloses a display device comprising a bezel, a cell, at least one film, a light bar and a composite backlight module. The composite backlight module comprises a plurality of connecting structures coupled with the bezel for fixing and protecting the cell, a containing space for containing the cell and the film, and a light guide portion for guiding light emitted by the light bar to a light exit surface of the composite backlight module. The composite backlight module is made of a same material by injection molding.