Plastic Frame with Integral Light Guide for Backlight Modules
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Solution Overview
Problem
The existing backlight modules in thin electronic devices, such as tablets and smartphones, face design and manufacturing challenges due to irregularities caused by increasing the height of only one end of the light guiding plate to match the LEDs, leading to increased costs and complexity in assembly and manufacturing.
Innovation Solution
A plastic frame is manufactured using a co-injection molding process, where a light guiding element with a first end matching the height of the illuminating elements and a second end matching the light guiding plate is integrally combined with the frame body, eliminating the height difference and ensuring even light distribution without irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the height of one end of the light guiding plate is increased to match the LEDs, then light leakage is prevented and light utilization is enhanced, but the shape of the light guiding plate becomes irregular, increasing design and manufacturing costs
Solution Approach 1:
The patent merges the light guiding plate with the frame body by forming the light guiding element as an integral part of the frame structure through co-injection molding. This integration eliminates the need for separate light guiding plates with irregular shapes, thereby preventing light leakage while maintaining regular geometry and reducing manufacturing complexity.
Solution Approach 2:
The patent employs composite materials by combining different plastic materials with distinct properties in a single co-injection molding process. The frame body material provides structural support while the light guiding element material provides optical transmission, achieving both mechanical integrity and optical functionality without requiring separate components.
2Use of energy by moving object
If the height of one end of the light guiding plate is increased to match the LEDs, then light utilization is enhanced, but the entire shape of the light guiding plate becomes irregular, increasing assembly complexity
Solution Approach 1:
By merging the light guiding function into the frame structure itself, the patent eliminates the need for separate light guiding plates with varying heights. The integrated light guiding element maintains a regular shape while still providing the necessary light transmission paths, thereby reducing assembly complexity.
Solution Approach 2:
The patent applies local quality by providing different heights at different locations of the light guiding element to match the LED heights locally, while maintaining an overall regular shape. This allows light utilization to be optimized at critical interfaces without compromising the overall geometric regularity needed for simple assembly.
3Ease of manufacture
If separate components are used for the frame body and light guiding plate, then manufacturing flexibility is maintained, but assembly steps and costs increase
Solution Approach 1:
The patent combines the frame body and light guiding plate into a single integrated component manufactured through co-injection molding. This integration eliminates multiple assembly steps while maintaining manufacturing flexibility through the ability to design the integrated structure to fit different LED configurations. The single-piece construction directly improves assembly efficiency by removing the need for separate assembly operations.
Data Source
AI summary
A plastic frame, a display having the same and a method for manufacturing the plastic frame are disclosed, wherein the display has a display module and a backlight module. The display module connects to the backlight module, and the backlight module has a light guiding plate, illuminating elements, and a plastic frame. The plastic frame has a frame body and a light guiding element. The frame body is made of plastics and the light guiding plate and the illuminating elements are accommodated therein. The light guiding element has a first end and a second end, is made of light optically transmissive material, and is integrally formed. The height of the first end is H1 and the height of the second end is H2, wherein H1>H2, and the light guiding plate is disposed near the second end.