Integrated Reflective Back Cover for Thin Laptop Modules
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Solution Overview
Problem
The existing backlight modules for miniaturized laptops face challenges in reducing thickness due to multiple assembling frames and are affected by the size of the reflector, which complicates assembly and increases thickness, while the plastic frame adds complexity and components.
Innovation Solution
A reflective back cover integrates a reflector, a metal cover, and a plastic frame as an integral component, featuring a concave design to position and retain the light component and guide plate, reducing the number of components and simplifying assembly, made from polyethylene Terephthalate with micro cellular structures for improved light reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple assembling frames (metal back cover, plastic frame, reflector) are used to assemble the backlight module components, then the structural stability and component positioning are improved, but the overall thickness and device complexity increase
Solution Approach 1:
The patent combines the metal back cover, plastic frame, and reflector into a single integrated back cover component. This merging eliminates the need for multiple separate frames and their associated assembly processes, thereby reducing the overall thickness while maintaining structural stability through the unified design.
Solution Approach 2:
The integrated back cover serves multiple functions simultaneously: it provides structural support (replacing the metal back cover), positions components (replacing the plastic frame), and reflects light (replacing the separate reflector). This multi-functionality reduces the number of components needed while maintaining all necessary structural and optical functions.
2Manufacturing precision
If a separate plastic frame is used for assembling and positioning optical films and the panel module, then the positioning precision is improved, but the number of components and assembly complexity increase
Solution Approach 1:
The positioning frame function previously performed by a separate plastic frame is merged into the integrated back cover. The back cover includes integrated positioning structures such as recesses and protrusions that directly position the optical films and panel module, eliminating the need for a separate plastic frame while maintaining positioning precision.
Solution Approach 2:
The integrated back cover incorporates segmented positioning features (recesses, protrusions, and guide structures) that are distributed throughout the component. These segmented features provide precise positioning for different components at specific locations without requiring a separate framing structure.
3Use of energy by moving object
If a separate reflector is used to reflect scattered lights from the light guide plate, then the light reflection efficiency is improved, but the overall thickness and component count increase
Solution Approach 1:
The reflector function is merged into the integrated back cover by incorporating a reflective layer or reflective surface on the inner side of the back cover. This eliminates the need for a separate reflector component while maintaining light reflection efficiency, as the reflective surface is positioned optimally within the integrated structure.
Solution Approach 2:
The integrated back cover performs multiple functions including structural support, component positioning, and light reflection. The reflective surface is integrated into the back cover design, allowing it to reflect scattered lights from the light guide plate while simultaneously serving as the structural back cover, thereby eliminating the need for a separate reflector component.
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
This solution reduces the thickness of the backlight module, enhances manufacturing efficiency, and provides a reliable assembly process by integrating multiple functions into a single component, improving light reflection and reducing manufacturing costs.
Implementation Method 1
The reflective back cover is utilized for reflecting the light source emitted from the light component and the light guide plate
Data Source
AI summary
A reflective back cover made of plastic material having micro cellular structures is processed by compression molding and cutting so as to have a monolithical structure. The white material of the reflective back cover reflects lights such that the back cover can be an integral component featuring multiple functions of various components. With the thickness control of the reflective back cover, a concave can be formed at the side of the back cover where a light source is contained and the concave further retains the light source and its flexible printed circuit board. With the incorporation of the reflective back cover, the thickness of the backlight module can be reduced and a reliable and repetitive manufacturing of the backlight module can be introduced.