Curved Backlight Module Narrow Bezel Design
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Solution Overview
Problem
Conventional direct-lit backlight modules face challenges in achieving a narrow bezel design due to structural limitations, and the use of flat diffuser plates in curved backlight modules results in instability and optical quality issues due to rebound stress.
Innovation Solution
A curved backlight module design featuring a frame unit with a back frame, a curvature fixing member, and a diffuser plate, where the curvature fixing member presses the diffuser plate to form a curved shape, and the diffuser plate has positioning structures that align with the frame unit to stabilize the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional spacers or positioning blocks are used to fix the diffuser plate and optical film, then positioning is achieved, but the structural space around the backlight module is occupied, preventing narrow bezel design
Solution Approach 1:
The patent combines the positioning function and the curvature fixing function into a single integrated structure. The curvature fixing member includes positioning protrusions that engage with positioning grooves on the diffuser plate, eliminating the need for separate spacers or positioning blocks. This merging of functions removes unnecessary components and reduces the overall structural space, enabling narrow bezel design while maintaining accurate positioning.
Solution Approach 2:
The patent extracts the positioning function from separate spacers or positioning blocks and integrates it directly into the curvature fixing member. By taking out the positioning function and combining it with the curvature fixing structure, the design eliminates redundant components that would otherwise occupy space around the backlight module, thereby achieving narrower bezels.
2Ease of manufacture
If a flat diffuser plate is used in a curved backlight module, then manufacturing is simpler, but rebound stress causes instability and affects optical quality
Solution Approach 1:
The patent applies preliminary action by pre-forming the diffuser plate with a curved shape that matches the desired final curvature of the backlight module. The diffuser plate is manufactured with a predetermined curvature rather than being flat, so that when installed, it naturally conforms to the curved surface without generating rebound stress. This preliminary shaping ensures both manufacturing feasibility and operational stability.
Solution Approach 2:
The patent changes the geometric parameter of the diffuser plate from flat to curved. By modifying the shape parameter of the diffuser plate to match the curvature requirements of the backlight module, the plate can be properly formed without generating rebound stress during assembly, thereby improving reliability while maintaining manufacturability through controlled curvature parameters.
3Manufacturing precision
If the diffuser plate is pressed to form curvature, then optical quality improves, but positioning accuracy becomes difficult to control
Solution Approach 1:
The patent introduces an intermediary mechanism in the form of positioning protrusions and positioning grooves. These intermediary features act as mediators between the curvature fixing member and the diffuser plate, ensuring that the pressing action for curvature formation is precisely guided and constrained. The positioning grooves on the diffuser plate engage with the positioning protrusions, providing accurate alignment and preventing lateral displacement during the pressing process, thus maintaining both curvature accuracy and positioning precision.
Data Source
AI summary
A curved backlight module includes a frame unit, a light source, and a diffuser plate. The frame unit includes a back frame, a curvature fixing member combined with the back frame, and at least one first positioning structure. The at least one first positioning structure is disposed on anyone of the back frame or the curvature fixing member. The curvature fixing member presses the diffuser plate so that at least a portion of the diffuser plate has the same curvature with the curvature fixing member. The diffuser plate has at least one second positioning structure, the at least one first positioning structure of the frame unit is combined with the at least one second positioning structure of the diffuser plate to limit the diffuser plate and simplify the structure of the positioning elements. The curvature fixing member stably maintains the curvature of the diffuser plate, thereby improving the overall structural stability and optical quality. The present invention further provides a display device including the curved backlight module.