Splicing Backplane Asymmetry for Uniform Thickness
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Solution Overview
Problem
Large-size backlight modules pose challenges in punch forming and splicing due to size and weight, requiring complex and costly assembly processes that affect reliability and economy.
Innovation Solution
A splicing backplane design featuring a mounting portion and a supporting portion with stepped surfaces and reinforcing elements, allowing for easy assembly and superposition of multiple backplanes without altering overall thickness, and reinforced by horizontal and vertical supports for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a monolithic backplane is used for large-size backlight modules, then structural strength is improved, but manufacturing complexity and cost increase due to requiring large-size punch forming molds
Solution Approach 1:
The backplane is divided into multiple standard-sized backplane units that can be independently manufactured using existing molds. These segmented units are then assembled together to form the complete backplane structure, eliminating the need for complex large-size punch forming molds while maintaining overall structural strength through the modular assembly approach.
2Adaptability or versatility
If multiple backplanes are spliced together, then assembly flexibility is improved, but structural stability deteriorates due to potential misalignment and deformation
Solution Approach 1:
The backplane units are designed with asymmetric stepped surfaces featuring different height differences on adjacent sides. This asymmetric design creates a unique interlocking geometry when backplanes are spliced together, ensuring proper alignment and preventing deformation while maintaining assembly flexibility. The asymmetric stepped surfaces guide the assembly process and ensure stable connections between multiple units.
3Ease of operation
If stepped surfaces with equal height differences are used for splicing backplanes, then assembly simplicity is improved, but thickness uniformity deteriorates
Solution Approach 1:
The stepped surfaces are designed with asymmetric height differences where adjacent stepped surfaces have different heights. This asymmetric design ensures that when backplanes are spliced together, the varying height differences compensate for each other, maintaining uniform overall thickness while keeping the assembly process simple. The asymmetric stepped surfaces naturally guide alignment during assembly.
4Strength
If reinforcing supports are added to splicing backplanes, then structural intensity is improved, but device complexity increases
Solution Approach 1:
The reinforcing supports are integrated into the backplane structure itself, merging the support function with the existing backplane units. The reinforcing supports are designed as part of the modular assembly, combining multiple functions (structural support, alignment, and reinforcement) into a unified design that increases structural intensity without proportionally increasing device complexity.
Data Source
AI summary
The invention provides a splicing backplane for a backlight module, which is arranged on the backside of the backlight module. The splicing backplane comprises a mounting portion and a supporting portion, wherein the horizontal height of the mounting portion is level with or lower than that of the supporting portion; and a plurality of the splicing backplanes are assembled together by the mutual superposition of various mounting portions. A plurality of the splicing backplanes are superposed with each other and combined into one, and the height differences between the mounting portions and the supporting portions of two adjacent backplanes are unequal, so that one backplane can be accommodated into the other backplane. In addition, after the superposition, the overall thickness of the backplanes is invariable.