Composite Display Panel Frame Structure for Warping Control
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Solution Overview
Problem
Existing ultra-thin large screen display devices face issues with structural rigidity, warping due to thermal deformation, damage from thermal deformation, exposure of side surfaces, and leakage of hot-melt adhesive during ultrasonic welding.
Innovation Solution
A display device structure comprising a display panel, a material complexed panel with fibers, and a side frame that includes horizontal and vertical parts, where the material complexed panel has an outer part recessed from its front surface, allowing for ultrasonic welding and preventing adhesive leakage and thermal exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the display device is made ultra-thin, then the profile is thinner and more compact, but structural rigidity deteriorates and warping occurs due to thermal deformation
Solution Approach 1:
The patent employs a composite panel structure consisting of multiple layers including a display panel, a first panel, a second panel, and a third panel. These layers are coupled together to form a material complexed panel that provides both ultra-thin profile and sufficient structural rigidity. The composite structure distributes thermal stresses and prevents warping while maintaining overall thinness.
Solution Approach 2:
The panel assembly is divided into multiple functional segments: the display panel for image display, the first panel (material complexed panel) for structural support, the second panel for additional reinforcement, and the third panel for edge protection. This segmentation allows each component to be optimized for its specific function while collectively achieving both thinness and rigidity.
2Device complexity
If the panel structure is simplified for ultra-thin design, then manufacturing is easier, but warping due to thermal deformation increases
Solution Approach 1:
The patent uses a composite panel structure with multiple layers of different materials coupled together. This composite construction provides inherent resistance to thermal deformation through the differential expansion properties of the layered materials, maintaining stability without requiring complex internal reinforcement structures.
Solution Approach 2:
The patent addresses warping resistance by extending the structural solution into the vertical dimension through multiple coupled panels rather than increasing horizontal complexity. The stacked panel configuration provides thermal stability through layering, maintaining simplicity in the planar view while achieving rigidity through the third dimension.
3Length of stationary object
If the side frame is positioned close to the display panel for compactness, then the profile is more compact, but thermal deformation damage increases
Solution Approach 1:
The patent introduces a vertical spacing dimension between the display panel and side frame by incorporating the first and second panels as spacers. This creates a controlled air gap that provides thermal isolation while maintaining compact horizontal dimensions, effectively using the third dimension to resolve the conflict between compactness and thermal protection.
Solution Approach 2:
The first and second panels serve as intermediary structures between the display panel and the side frame. These intermediate layers provide thermal buffering and mechanical coupling, protecting the display panel from direct thermal exposure while maintaining the compact overall structure.
4Strength
If hot-melt adhesive is used for ultrasonic welding, then bonding is stronger, but adhesive leakage occurs
Solution Approach 1:
The patent incorporates a groove structure in advance during panel fabrication. This pre-formed groove is specifically designed to contain the hot-melt adhesive during the ultrasonic welding process, allowing strong bonding while preventing leakage. The groove acts as a built-in containment feature that addresses the leakage issue before the welding process occurs.
5Ease of manufacture
If the panel edges are left exposed for simplicity, then manufacturing is simpler, but side surfaces become exposed which is aesthetically undesirable
Solution Approach 1:
The third panel serves multiple functions simultaneously: it provides structural reinforcement to the edge, conceals the exposed side surfaces for aesthetic purposes, and maintains the overall compact structure. This multi-functional component achieves both manufacturing simplicity and aesthetic appeal without requiring separate elements for each function.
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 structure provides structural rigidity, minimizes warping and damage, maintains flatness, and prevents adhesive leakage and thermal exposure, ensuring a stable and aesthetically pleasing display device.
Implementation Method 1
the horizontal part may be coupled to the outer part
Data Source
AI summary
A display device is disclosed. The display device may include: a display panel; a material complexed panel positioned behind the display panel, to which the display panel is coupled, and including fibers; and a side frame extending along a periphery of the material complexed panel, the side frame including: a horizontal part positioned between the display panel and the material complexed panel; and a vertical part intersecting the horizontal part and covering a side surface of the material complexed panel, wherein the material complexed panel may include an outer part adjacent to the periphery of the material complexed panel and formed by being recessed rearward from a front surface of the material complexed panel, and the horizontal part may face the outer part and may be coupled to the outer part.