Curved LED Plate Support Structure for Mura-Free Displays
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Solution Overview
Problem
Variation in optical distance between LED plates and a diffuser plate in display apparatuses leads to mura (image defects) due to inconsistent light distribution, which is caused by central portions of LED plates lifting off the rear chassis, resulting in varying optical distances.
Innovation Solution
A support member, such as a beading or support member, is provided on the rear chassis to support the edges of LED plates at their boundaries, maintaining consistent optical distance by preventing central portions from lifting and ensuring uniform light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If LED plates are mounted on the rear chassis without support members, then the device complexity is reduced, but the optical distance variation increases causing mura defects
Solution Approach 1:
A support member is introduced as an intermediary component between the LED plates and the rear chassis. This support member provides targeted support at the boundaries of LED plates, preventing central portions from lifting while maintaining overall structural simplicity. The support member acts as a mediator that resolves the conflict between simple mounting structures and uniform optical distance requirements.
2Manufacturing precision
If support members are added to maintain optical distance, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The support member is strategically positioned only at the boundaries between LED plates rather than providing uniform support across the entire rear chassis. This localized support approach maintains optical distance uniformity where it is most critical (at plate boundaries) while minimizing overall structural complexity. The support configuration provides precise control with minimal added components.
3Ease of manufacture
If the LED plates are allowed to flex freely, then the ease of manufacture improves, but the stability of the optical distance deteriorates
Solution Approach 1:
The support members are pre-installed on the rear chassis before mounting the LED plates. This preliminary action ensures that the support structure is already in place to maintain proper optical distance, allowing LED plates to be simply placed onto the supported positions. The support members are positioned in advance to guide proper LED plate placement and maintain stable optical distance from the beginning.
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 solution effectively reduces optical distance variation, preventing mura on the display panel by maintaining consistent light distribution and reducing material costs through targeted support member placement.
Implementation Method 1
a diffuser plate on a front side of the plurality of LED plates and configured to diffuse light incident from the plurality of LEDs
Data Source
AI summary
A display apparatus includes: a rear chassis having curvature; a plurality of LED plates including a flexible material to be fastened to the front of the rear chassis in a shape corresponding to a shape of the rear chassis, and having a plurality of LEDs mounted thereon; and a diffuser plate on the front of the plurality of LED plates to diffuse light incident from the plurality of LEDs; and a support member on the front side of the rear chassis and configured to support a rear side of the plurality of LED plates and support edges of the plurality of LED plates at boundaries between the plurality of LED plates.