Flexible Holder Structure for Backlight Module Lamp Retention

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Solution Overview

Problem

Conventional holder structures for backlight modules are inefficient in retaining lamps and power wires, leading to loose connections, damage during assembly, and high manufacturing costs due to complex assembly processes and low yield.

Innovation Solution

A holder structure with flexible orienting slots and grooves that accommodate lamps and power wires, allowing for easy assembly and reassembly, and a reflector with protrusions to securely retain components, preventing damage and ensuring firm retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional holder structure with rigid fixture portions is used, then the lamp and power wire assembly can be positioned, but the structure becomes complex and difficult to assemble, and the connections may become loose under external force

Engineering Contradiction:

Improveconnection stabilityVSAvoidholder structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the material parameter of the holder structure from rigid to flexible, allowing the holder to deform elastically during assembly and operation. This flexibility enables the holder to accommodate dimensional variations and thermal expansion while maintaining secure connections, thereby improving reliability without increasing structural complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces dynamic characteristics to the holder structure through flexible materials that can adapt their shape and stiffness based on operational conditions. The holder transitions from a static rigid structure to a dynamic flexible structure that can respond to external forces and maintain connection stability throughout the product lifecycle

Inventive Principle:

Principle #15Dynamics

2Reliability

If a conventional holder structure with fixed positioning is used, then the lamp can be retained, but the assembly process becomes time-consuming and laborious with low manufacturing yield

Engineering Contradiction:

Improvelamp retentionVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The flexible holder structure allows for dynamic adjustment during assembly, enabling workers to quickly position and secure lamps without complex alignment procedures. The material's elasticity permits tolerance in positioning, significantly reducing assembly time and improving productivity while maintaining reliable lamp retention

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

By changing the material properties to flexible, the holder can be rapidly formed and adjusted during assembly operations, eliminating time-consuming rigid alignment processes while maintaining secure lamp retention, thus improving manufacturing yield and assembly efficiency

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If a conventional holder structure is used, then components can be positioned, but the solder points and lamps are vulnerable to damage during assembly and reassembly

Engineering Contradiction:

Improvepositioning accuracyVSAvoiddamage risk to solder points

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The flexible holder structure provides beforehand cushioning by absorbing mechanical stresses and impacts during assembly and operation. The material's elasticity acts as a buffer that protects fragile solder points and lamps from damage before failures can occur, thereby reducing harmful factors while maintaining positioning accuracy

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Reliability

If a rigid holder structure is used, then the lamp and wires can be retained, but the structure cannot accommodate dimensional variations and thermal expansion

Engineering Contradiction:

Improvecomponent retentionVSAvoiddimensional variation accommodation

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the material parameter from rigid to flexible, enabling the holder to accommodate dimensional variations and thermal expansion through elastic deformation. This material parameter change allows the holder to adapt to different component sizes and thermal conditions while maintaining secure retention, thereby improving both reliability and adaptability

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS7597463B2Holder structure

Publication Date: 2009.10.06 AU OPTRONICS CORP

AI summary

The present invention discloses a holder structure for retaining at least one lamp and associated wire within a backlight module, which includes a main body, a reflector, and a first groove formed on an external sidewall of the main body. The main body has at least one first orienting slot for accommodating the lamp therein, and a second orienting slot for accommodating a high-voltage power wire therein. Said first groove communicates with the first and second orienting slots to divide a lateral slot wall of each of the first and second orienting slots into two opposite flexible walls which can provide flexibility required for assembly of the lamp and associated wire. Each two opposite flexible walls have two protrusions respectively formed on the outsides thereof for hooking with corresponding openings defined on the reflector, whereby the lamp and power wires are able to be firmly retained in the associated slots, respectively.