Corrugated Display Panel Structure for Rigidity and Surface Quality
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Solution Overview
Problem
Existing display devices face challenges in achieving both high rigidity and light weight, particularly in large-sized displays, while maintaining appearance quality during manufacturing processes.
Innovation Solution
A display device design incorporating a corrugated panel with a first and second skin layer and a core layer, featuring openings in at least one of the skin layers to enhance bending and torsional rigidity, and a back cover that encloses the panel, allowing stress dispersion during manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large-sized display device uses a traditional flat panel structure, then the device can be manufactured simply, but the rigidity is insufficient and the device becomes heavy
Solution Approach 1:
The panel structure is segmented into multiple functional layers: a front cover, a rear cover, and a corrugated panel with skin layers and core layers. This segmentation allows each layer to perform specific functions (protection, rigidity, light transmission) while collectively achieving high rigidity without excessive weight
Solution Approach 2:
The corrugated panel employs composite material structure with skin layers (transparent resin) and core layers (honeycomb structure or air spaces). This composite design provides high strength-to-weight ratio and superior rigidity compared to traditional flat panels, resolving the contradiction between rigidity and structural complexity
2Manufacturing precision
If the corrugated panel uses a solid structure without openings, then the rigidity is high, but the appearance quality deteriorates during manufacturing processes
Solution Approach 1:
Openings are strategically introduced only in specific regions of the corrugated panel where they serve functional purposes (stress relief during manufacturing, light transmission for display effects) rather than uniformly throughout. This local modification maintains rigidity in critical areas while improving appearance quality and manufacturing precision in other areas
3Manufacturing precision
If openings are added to the skin layers of the corrugated panel, then the appearance quality is maintained during manufacturing, but the structural integrity may be compromised
Solution Approach 1:
The skin layers are designed with a porous structure containing multiple openings. This porous design allows stress to disperse during manufacturing processes like pressing, preventing appearance defects. The openings are strategically positioned and sized to maintain overall structural integrity while enabling stress relief, thus resolving the contradiction between manufacturing precision and structural reliability
Data Source
AI summary
According to an aspect of the present disclosure, a display device includes a display panel configured to display an image; a corrugated panel on a rear surface of the display panel, the corrugated panel comprising a first skin layer, a second skin layer, and a core layer between the first skin layer and the second skin layer; and a back cover that encloses the display panel and the corrugated panel, wherein at least one of the first skin layer or the second skin layer comprises an opening through a thickness of the at least one of the first skin layer or the second skin layer to improve the appearance quality of the display device.