Elastic Mold Frame for Impact and Vibration Protection
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Solution Overview
Problem
Existing mold frames for backlight units are expensive to manufacture, take a long time to develop, and lack impact absorption performance, leading to potential damage to liquid crystal panels during high vibration and drop tests.
Innovation Solution
An elastic mold frame made of silicone or rubber, featuring a bumper portion and mounting portion to protect the liquid crystal panel from impact and vibration, with separate injection-molded components for improved fit and reduced manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic material is used for the mold frame, then the manufacturing cost of the mold is reduced, but the impact absorption performance is insufficient leading to product defects
Solution Approach 1:
The mold frame is constructed using a composite structure combining a rigid skeleton (metal or rigid plastic) providing structural strength with an elastic coating layer (rubber or silicone) providing impact absorption. This composite approach allows the frame to maintain structural integrity while effectively absorbing impacts, resolving the contradiction between manufacturing ease and reliability.
Solution Approach 2:
The invention changes the material parameters of the mold frame by introducing elastic materials (rubber or silicone) with specific elasticity values into the frame structure. This parameter change enables the frame to deform elastically under impact, absorbing energy while maintaining structural integrity, thus improving impact absorption performance without sacrificing manufacturability.
2Manufacturing precision
If an expensive injection mold is manufactured for the mold frame, then the manufacturing precision is improved, but the development time and investment cost increase
Solution Approach 1:
The mold frame is divided into two functional segments: a rigid skeleton providing structural precision and an elastic coating layer providing impact absorption. This segmentation allows the rigid skeleton to be manufactured with standard precision using simpler, faster processes, while the elastic layer is added separately, reducing overall development time and investment cost while maintaining necessary manufacturing precision.
Solution Approach 2:
The invention replaces the need for expensive, precision-critical injection molds with a simpler rigid skeleton structure that can be manufactured using less expensive tools. The elastic coating layer is then applied to provide the necessary protective function, effectively replacing the need for high-precision molding and reducing both development time and investment cost.
3Strength
If a rigid plastic mold frame is used, then the structural strength is maintained, but the vibration resistance is insufficient causing damage to the liquid crystal panel
Solution Approach 1:
The mold frame combines a rigid skeleton maintaining structural strength with an elastic coating layer that absorbs vibration energy. The rigid skeleton provides the necessary structural support, while the elastic layer dampens vibrations through deformation, protecting the liquid crystal panel from vibration-induced damage.
Solution Approach 2:
The elastic coating layer is applied beforehand to the rigid skeleton, creating a cushioning layer that absorbs and dissipates vibration energy before it can reach the liquid crystal panel. This prior cushioning prevents vibration damage while maintaining the structural strength of the rigid skeleton.
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
Enhances protection of liquid crystal panels from impact and vibration, reduces manufacturing time and costs, and improves reliability by using a more flexible and durable material.
Implementation Method 1
an elastic mold frame made of an elastic material... improved protection performance for protecting a liquid crystal panel from impact and vibration
Implementation Method 2
an elastic mold frame made of an elastic material... improved protection performance for protecting a liquid crystal panel from impact and vibration
Data Source
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AI summary
A backlight unit according to an embodiment of the present invention comprises an optical sheet, a bottom chassis including a back plate and a side wall and having an accommodating space therein, a light source module accommodated in the accommodating space and disposed between the optical sheet and the back plate to irradiate light and an elastic mold frame including a mounting portion coupled to the side wall of the bottom chassis and extending from an outer side of the optical sheet toward an inner side of the optical sheet, and a bumper portion protruded in a stepped manner from an outer side of the mounting portion toward a front side, the elastic mold frame including silicone or rubber. According to one embodiment of the present invention, the protective performance for protecting the liquid crystal panel from impact and vibration is improved, and the time required for manufacturing is reduced.