Backlight Unit Diffusion Sheet Overlap Design
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Solution Overview
Problem
The existing backlight units for LCD devices suffer from brightness deterioration due to gaps between components, which increase manufacturing time and costs, particularly due to the use of additional parts like the light reflection housing and adhesive tapes.
Innovation Solution
A backlight unit design featuring a bottom cover with LEDs, a light guide plate, and a diffusion sheet with a reflection material layer on its upper surface, overlapping the support main, which prevents light leakage and eliminates the need for additional adhesive tapes, thereby enhancing brightness and reducing assembly time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a light reflection housing and adhesive tapes are used to prevent light leakage, then light leakage is reduced, but manufacturing time and costs increase
Solution Approach 1:
The patent merges the light reflection housing and adhesive tape functions into a single integrated diffusion sheet structure. The diffusion sheet is designed with a specific shape that directly overlaps and contacts the support main, eliminating the need for separate light reflection housing and adhesive tapes while maintaining light leakage prevention functionality.
Solution Approach 2:
The patent extracts and eliminates unnecessary components (light reflection housing and adhesive tapes) by incorporating their functions into the diffusion sheet. The diffusion sheet alone is configured to prevent light leakage through its overlapping arrangement with the support main, removing redundant parts and simplifying the assembly process.
2Object-affected harmful factors
If a light reflection housing and adhesive tapes are used to prevent light leakage, then light leakage is reduced, but manufacturing costs increase
Solution Approach 1:
The patent combines multiple components (diffusion sheet, light reflection housing, and adhesive tape) into a single integrated diffusion sheet structure. This reduction in component count directly lowers manufacturing costs while maintaining the light leakage prevention function through the diffusion sheet's overlapping configuration with the support main.
Solution Approach 2:
The patent removes unnecessary components (light reflection housing and adhesive tapes) that increase manufacturing complexity and cost. The diffusion sheet is designed to independently perform both diffusion and light leakage prevention functions, eliminating the need for additional parts and reducing overall manufacturing expenses.
3Device complexity
If gaps exist between light reflection housing and light guide plate, then assembly is simpler, but brightness deteriorates
Solution Approach 1:
The patent applies local quality by configuring the diffusion sheet with specific overlapping areas that contact the support main at critical locations. This localized overlapping arrangement prevents light leakage in specific regions where gaps would otherwise occur, improving brightness without requiring complex assembly of additional components throughout the entire structure.
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 proposed design improves light uniformity and reduces manufacturing time and costs by eliminating gaps and additional adhesive tapes, resulting in enhanced brightness and efficiency.
Implementation Method 1
a reflection material layer is formed on an upper surface of the diffusion sheet corresponding to the overlapped area
Data Source
AI summary
A backlight unit adapted to enhance brightness and reduce manufacturing time and costs is disclosed. The backlight unit includes a bottom cover with an opened upper surface, a plurality of light emission diodes arranged on an inner edge of the bottom cover, a light guide plate disposed parallel to the plurality of light emission diodes, and a diffusion sheet disposed on the light guide plate. The diffusion sheet is provided to have an overlapped area with a support main which is combined with the bottom cover. Also, a reflection material layer is formed on an upper surface of the diffusion sheet corresponding to the overlapped area.