Narrow Border Backlight Module Integrated Frame
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Solution Overview
Problem
Conventional LCD backlight modules face challenges in assembly efficiency and frame thickness due to separate manufacturing and inaccurate positioning of components, leading to increased assembly time and reduced yield rates.
Innovation Solution
A narrow border backlight module design that integrates a frame with a reflective isolation layer and a light guide element, formed through insert molding, which includes a receiving space for a light emitting unit and microstructures, reducing the frame thickness and preventing short circuits, and uses a protrusion and optical film engagement mechanism for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate manufacturing and assembly of frame and light guide element are used, then manufacturing flexibility is maintained, but assembly time increases and positioning accuracy decreases
Solution Approach 1:
The frame and light guide element are integrally formed as a single structure through injection molding, eliminating the separate assembly step. The light guide element is directly formed within the frame structure during the same manufacturing process, achieving both improved assembly efficiency and positioning accuracy while maintaining manufacturing flexibility.
2Manufacturing precision
If conventional separate assembly method is used, then manufacturing simplicity is maintained, but yield rate decreases due to inaccurate positioning
Solution Approach 1:
By integrating the light guide element formation into the frame manufacturing process through injection molding, the patent eliminates positioning errors associated with separate assembly. The light guide element is precisely formed in its final position within the frame structure, achieving high manufacturing precision without significantly complicating the manufacturing process.
3Length of stationary object
If frame thickness is reduced for compactness, then LCD compactness is improved, but structural strength and assembly stability may be compromised
Solution Approach 1:
The frame is constructed using composite materials, specifically a metal substrate providing structural strength and a polymeric light guide material providing optical functionality. This composite structure allows for reduced frame thickness while maintaining adequate structural strength through the inherent properties of the metal substrate and the integrated design of the composite construction.
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 integrated manufacturing process reduces assembly time, minimizes frame thickness, and prevents short circuits by using a reflective isolation layer and efficient optical film fixation, enhancing light utilization and assembly stability.
Implementation Method 1
The reflective isolation layer is disposed on an inner surface facing the cavity of the sidewalls
Implementation Method 2
The light guide element is formed inside the frame, and the light guide element and the frame are integrally formed
Data Source
AI summary
A narrow border backlight module includes a frame, a reflective isolation layer, and a light guide element. The frame includes a plural of sidewalls connected to each other, and the bottom of the frame is hollow. The sidewalls define a cavity. The reflective isolation layer is disposed on an inner surface facing the cavity of the sidewalls. The light guide element is formed inside the frame, and the light guide element and the frame are integrally formed.