Backlight Unit Reflecting Plate Design for Thin Displays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display devices face challenges in reducing thickness and manufacturing costs due to the structural limitations of traditional backlight units, which require a printed circuit board (PCB) for mounting a light source and a reflecting plate, leading to increased thickness and complexity.
Innovation Solution
A backlight unit design that replaces the PCB with a reflecting plate, where a light source is mounted directly on the plate with a first metal pattern on one surface and a second metal pattern on the other, forming a bent or curved surface to enhance light reflection and eliminate the need for additional attachments, using materials like foamed polyethylene terephthalate (PET) or filler-inserted PET.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a PCB is used for mounting light sources, then the light source can be securely mounted and electrically connected, but the thickness of the backlight unit increases
Solution Approach 1:
The patent removes the PCB from the backlight unit structure, extracting the light source mounting function directly onto the reflecting plate. This eliminates the need for a separate PCB layer, thereby reducing the overall thickness while maintaining the essential functions of light source support and electrical connection.
Solution Approach 2:
The patent combines multiple functions into the reflecting plate: it serves as both the reflective surface and the mounting substrate for the light sources. By integrating the light source installation function into the reflecting plate itself, the structure is simplified and thickness is reduced without compromising functionality.
2Ease of manufacture
If a PCB with insulator core and metal deposition is used, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the expensive PCB component (insulator core with metal deposition) from the structure and replaces it with a simpler reflecting plate that performs the same mounting and electrical connection functions, thereby reducing manufacturing cost.
Solution Approach 2:
The patent replaces the costly PCB with a more economical reflecting plate structure that achieves the same functional objectives at lower material and manufacturing costs, making the overall backlight unit more cost-effective.
3Length of moving object
If a reflecting plate is attached to PCB with adhesive tape, then the reflecting plate is secured, but the thickness increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the reflecting plate and light source mounting functions into a single integrated structure, eliminating the need for separate attachment steps using adhesive tape. This integration simplifies the manufacturing process and reduces the overall thickness by removing unnecessary intermediate layers.
Solution Approach 2:
The patent removes the adhesive tape layer from the structure by directly integrating the light source mounting function into the reflecting plate, thereby eliminating this intermediate component and reducing the overall thickness of the backlight unit.
4Illumination intensity
If PSR coated on PCB is used, then electrical resistance is achieved, but light reflection efficiency decreases
Solution Approach 1:
The patent combines the electrical connection function and light reflection function into a single integrated structure on the reflecting plate, eliminating the need for PSR coating. This integration ensures both reliable electrical connection and high light reflection efficiency without the compromises required by separate components.
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 design significantly reduces the thickness of the backlight unit, simplifies the manufacturing process, minimizes light leakage, and enhances light reflection efficiency, allowing for thinner and more cost-effective display devices.
Implementation Method 1
a reflecting plate on which a light source is mounted
Implementation Method 2
a first metal pattern formed on one surface of the reflecting plate such that the first metal pattern is in contact with the light source; and a second metal pattern formed on the other surface of the reflecting plate and electrically connected to the first metal pattern
Data Source
AI summary
Disclosed is a backlight unit comprising: a reflecting plate having a light source seated thereon; a first metal pattern formed on one surface of the reflecting plate so as to make contact with the light source; and a second metal pattern formed on the other surface of the reflecting plate and electrically connected to the first metal pattern.