Curved Rear Chassis Segmentation for Optical Sheet Wrinkle Prevention
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Solution Overview
Problem
Manufacturing a curved chassis with a certain thickness for display apparatuses is challenging, as existing methods struggle to produce a single, curved unit with optimal thickness and shape, leading to reduced display quality due to wrinkled optical sheets.
Innovation Solution
A display apparatus design featuring a rear chassis with a backplate, upper frame, and lower frame that can be removably coupled and curved to match the curvature of the display, using fastening members and slits for flexibility, along with a middle mold to support the display panel and diffusion plate, preventing wrinkles in optical sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a single curved chassis is manufactured to accommodate display components, then the display can be curved, but it is difficult to manufacture with certain thickness and proper curvature in a single process
Solution Approach 1:
The chassis is divided into multiple separable components including a backplate, upper frame, and lower frame. Each component can be manufactured separately using standard processes, then assembled to form the complete curved chassis structure, eliminating the difficulty of manufacturing a single complex curved piece.
Solution Approach 2:
The frame components include slits that provide flexibility, allowing the rigid frame pieces to be bent and adjusted to match the curved backplate. This dynamic adjustment capability enables the assembly to achieve the desired curved shape without requiring complex curved manufacturing processes for each component.
2Volume of moving object
If the chassis is made thick enough to accommodate components, then components can be housed, but the curvature and thickness are difficult to achieve in a single manufacturing process
Solution Approach 1:
The thick chassis is segmented into a backplate and frame components that can be manufactured with standard thickness tolerances. The cumulative thickness of assembled components achieves the required overall thickness while avoiding the precision challenges of manufacturing a single thick curved piece.
Solution Approach 2:
The manufacturing approach changes from creating a single thick curved component to assembling multiple thinner components. This parameter change in manufacturing strategy allows standard manufacturing processes to be used while achieving the required overall thickness and curvature.
3Shape
If the display is curved, then lateral ends can protrude forward, but optical sheets may become wrinkled and display quality reduces
Solution Approach 1:
The optical sheets are positioned on the display panel rather than being integrated into the curved chassis structure. This separation allows the optical sheets to remain flat on the panel surface while the chassis components behind them provide the curved support structure.
Solution Approach 2:
The display panel acts as an intermediary between the curved chassis and the optical sheets. The panel provides a flat mounting surface for the optical sheets while the curved chassis supports the panel from behind, preventing direct contact between the curved structure and optical sheets that would cause wrinkling.
Data Source
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AI summary
A curved panel display in which an internal chassis (16) supporting a back-light assembly (12) and optical sheets (17) is produced as a curved unit to match the curvature of the final display. However, the chassis (16) needs to have a certain minimum thickness to support the components mounted on to it, and the thicker the chassis is, the more difficult its manufacture as a single unit becomes. In order to simplify manufacturing, the chassis is assembled from prefabricated components such as a rectangular back-plate (161), and frame segments (162, 163, 164) which are mounted at the edges of the back-plate. Either the backplate or the frame segments are prefabricated as curved components, so that, on assembly, the stiffer curved component forces the less stiff non-curved component(s) to bend thus achieving a curved unit. Alternatively, all the component parts are prefabricated as curved components.