Diffusion Plate Random Embossings Scratch Resistance
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Solution Overview
Problem
Existing diffusion plates in liquid crystal displays (LCDs) are prone to scratches and cracking during storage or transportation, which deteriorate display quality, and current solutions like adding beads or protective films either lead to display issues or increase manufacturing costs.
Innovation Solution
A diffusion plate with a base layer of optically transparent resin and a coating layer featuring random embossings on its surface, with a 60° gloss of 15% or less, to minimize contact stress and prevent cracking, while eliminating the need for additional protective films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If beads are added to the skin layer of the diffusion plate to form embossings, then the occurrence of scratches or cracking is reduced, but the beads are stripped from the skin layer and perceived as black spots, deteriorating display quality
Solution Approach 1:
The invention extracts the harmful beads from the system by not incorporating them into the diffusion plate structure. Instead of adding beads to form embossings (which cause black spots when stripped), the patent uses a different approach: forming embossings directly on the diffusion plate surface through a molding process without any bead materials, thereby eliminating the source of display degradation while maintaining scratch protection
Solution Approach 2:
The invention uses a cost-effective molding process to create embossings directly on the diffusion plate surface. The embossings are formed as an integral part of the diffusion plate structure through co-molding or post-molding processes, eliminating the need for expensive protective films or complex multi-layer structures with beads that are prone to failure
2Stability of the object's composition
If a protective film made of polyethylene is added to prevent bending due to moisture absorption, then the diffusion plate is protected from bending, but the manufacturing cost increases
Solution Approach 1:
The invention merges the protective function with the diffusion plate structure itself. By forming embossings directly on the diffusion plate surface through integration with the support structure, the patent combines structural support and protection into a single unified component, eliminating the need for separate protective films and reducing manufacturing complexity and cost
Solution Approach 2:
The embossed structure serves multiple functions simultaneously: it provides mechanical support, prevents bending, protects against moisture absorption, and maintains optical diffusion properties. This multi-functional design eliminates the need for separate protective films, reducing both manufacturing cost and structural complexity
3Ease of manufacture
If the diffusion plate surface is made smooth, then manufacturing is easier, but contact with the support causes scratches and cracking during storage or transportation
Solution Approach 1:
The invention applies preliminary action by forming embossings on the diffusion plate surface during the molding process itself, before the product enters storage or transportation. These pre-formed embossings create a protective rugged surface that prevents scratches and cracking from occurring during subsequent handling, while being integrated into the manufacturing process rather than added as a separate post-processing step
Data Source
AI summary
A diffusion plate that is capable of improving a display quality, and a backlight assembly and a liquid crystal display (“LCD”) including the same are disclosed. The diffusion plate includes a base layer including of a first optically transparent resin and a first coating layer provided on a first surface of the base layer. The first coating layer includes a second optically transparent resin and random embossings. The first surface including the embossings has a 60° gloss of 15% or less. A method of forming a diffusion plate includes forming a base layer including a first optically transparent resin, providing random embossings on the base layer and sizing the diffusion plate to predetermined dimensions.