Cut-and-Bend Frame for Miniaturized LCD Backlight Modules
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Solution Overview
Problem
Conventional edge-type backlight modules face challenges in miniaturization due to their thickness and require additional processing costs for structural strength and alignment features, making them difficult to manufacture cost-effectively.
Innovation Solution
A frame formed by cutting and bending a plate base with specific thickness and alignment features, including through holes and notches, which allows for direct formation of alignment and locking structures, reducing processing complexity and costs while maintaining mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reflective frame with great height is used to accommodate LED light bar, reflector, and LGP, then the structural strength is improved, but the thickness of the backlight module increases making miniaturization difficult
Solution Approach 1:
The frame integrates multiple functions into a single structure: it provides structural support, accommodates the LED light bar and reflector through integrated recesses, and directly contacts the LGP for optical coupling. This merging of functions eliminates the need for separate components and reduces overall thickness while maintaining strength.
Solution Approach 2:
The frame utilizes a plate-like structure with bending portions that create three-dimensional accommodation spaces within a thin profile. By bending portions of the plate base, the frame creates vertical recesses for the LED light bar and reflector without increasing the horizontal thickness, effectively using the vertical dimension to accommodate components.
2Strength
If an aluminum extruded heat sink is used to carry cushion pad and LCD panel, then structural strength and heat dissipation are improved, but additional processing costs are required for alignment notches and through holes
Solution Approach 1:
The frame is divided into distinct functional regions: a first plate element for structural support and component mounting, a second plate element for LCD panel support, and bending portions for alignment feature formation. This segmentation allows each region to be optimized independently and simplifies the manufacturing process by enabling localized feature creation.
Solution Approach 2:
Alignment notches and through holes are formed in the plate base before the bending process. By preparing these alignment features in advance on the flat plate base, subsequent bending operations can proceed without additional processing steps, reducing manufacturing complexity and costs.
3Volume of moving object
If components are miniaturized to reduce LCD module size, then the volume occupancy is improved, but the structural strength of components becomes weak
Solution Approach 1:
The frame employs a plate base material that combines high strength-to-weight ratio with formability. The material is selected to provide sufficient structural strength in miniaturized dimensions while allowing the frame to be formed through cutting and bending operations. The plate structure itself provides inherent strength through its geometry.
Solution Approach 2:
The frame incorporates bending portions with curved transitions instead of sharp angles. These curved features distribute stress more effectively and prevent stress concentration points that would weaken miniaturized components. The smooth transitions maintain structural integrity while enabling compact dimensions.
Data Source
AI summary
A frame formed by cutting and bending a plate base is provided. The maximum thickness of the frame is T, the thickness of the plate base is t, and 1.5t≦T≦2.5t. The frame includes a first plate element, a second plate element, and a bending portion. The second plate element is directly contacted to the first plate element, and the first plate element is substantially parallel to the second plate element. The bending portion is connected between the first plate element and the second plate element. A backlight module using the above-mentioned frame and a liquid crystal display (LCD) module using the backlight module are also provided.