Backlight Optical Sheet Stack with Tabs for Single-Step Assembly

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Solution Overview

Problem

Conventional backlight device assembly processes are inefficient due to sequential handling of optical components, leading to contamination, misalignment, and increased costs from packaging waste, while requiring multiple operators and restrictive environments to prevent thermal stress.

Innovation Solution

A prearranged stack of optical sheets with tabs for secure attachment to a mounting case, allowing single-operator assembly and reducing handling risks, with tabs enabling thermal expansion and contraction without optical artifacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If optical sheets are assembled sequentially by multiple operators, then each sheet can be individually positioned, but the assembly process becomes time-consuming and prone to contamination

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Multiple optical sheets are combined into a single integrated assembly unit with pre-attached tabs. This merging approach allows the entire stack to be positioned and aligned in one operation, eliminating the sequential handling of individual sheets while maintaining precise alignment through the integrated tab structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tabs are pre-attached to the optical sheets before assembly into the backlight unit. This preliminary action of preparing the optical sheets with attachment tabs in advance enables rapid one-step assembly, avoiding the need for multiple operators to individually position and align each sheet during the assembly process.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If optical sheets are handled separately by multiple operators, then each sheet can be individually adjusted, but the risk of contamination and damage increases

Engineering Contradiction:

ImproveadjustabilityVSAvoidyield rate

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Optical sheets are merged into a single stack with pre-attached tabs, reducing the number of handling operations from multiple individual sheet manipulations to one single stack placement. This significantly reduces the risk of contamination from fingerprints and dust, as well as scratch damages, while the tab design maintains the ability to adjust the entire stack as needed.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If optical sheets are mounted separately, then each sheet can be individually secured, but packaging waste and assembly costs increase

Engineering Contradiction:

Improveassembly flexibilityVSAvoidpackaging material waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

Multiple optical sheets are combined into a single integrated unit with shared tabs, eliminating the need for separate packaging for each individual sheet. This reduces packaging material waste significantly while the modular tab design maintains assembly flexibility, allowing the entire stack to be secured as one unit or adjusted as needed.

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If optical sheets are constrained tightly in the mounting case, then alignment is precise, but thermal expansion and contraction are restricted causing optical artifacts

Engineering Contradiction:

Improvealignment precisionVSAvoidthermal adaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The tab attachment system provides a dynamic mounting solution that allows optical sheets to expand and contract thermally while maintaining precise alignment. The tabs are secured to the mounting case in a way that constrains the optical sheets laterally for alignment precision but allows dimensional changes in the thickness direction due to thermal effects, preventing optical artifacts.

Inventive Principle:

Principle #15Dynamics

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 approach simplifies the assembly process, reduces manufacturing costs, and increases yield by minimizing operator-induced errors and packaging waste, while maintaining optical performance under varying conditions.

Implementation Method 1

a second optical sheet attached to the first optical sheet with an adhesive tape

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the assembled optical sheets must be able to freely expand and contract under varying conditions of temperature and humidity in order to release an induced thermal stress

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS7821590B2Assembly structure and process for a backlight device of a display system

Publication Date: 2010.10.26 INNOLUX CORP

AI summary

A backlight device comprises a mounting case and a stack of optical sheets attached to one another. The attached optical sheets includes at least a first optical sheet adhered with one or more tabs protruding from a side edge of a second optical sheet. The prearranged stack of attached optical sheets is assembled with the mounting case with one single placement operation conducted by one operator.