Display Device Top Case Segmentation and Resin Bonding
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Solution Overview
Problem
Existing display devices face challenges in reducing the bezel area while maintaining sufficient strength and cost-effectiveness, as current designs require large metal plates and additional connections to reinforce the top case, which increases material costs and does not adequately protect the display panel.
Innovation Solution
A display device with a top case composed of separated metal plates connected by thermoplastic resin, featuring a main frame with a patterned surface treatment and a sub frame made of thermoplastic resin, which reduces material waste, enhances bonding, and provides aesthetic appeal, eliminating the need for a bezel area by using a combination of metal and transparent thermoplastic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single top case made of metal plate is used to cover the display device, then the structural strength is sufficient, but the material cost increases and material waste occurs due to cutting
Solution Approach 1:
The top case is divided into multiple separate metal plates instead of using a single large plate. These plates are arranged to cover the display device and connected through resin, reducing material waste from cutting while maintaining structural strength through the distributed configuration.
2Area of stationary object
If the top case is made narrower to reduce bezel area, then the aesthetic quality improves, but the structural strength becomes insufficient
Solution Approach 1:
The top case uses a composite structure combining multiple metal plates with resin material. The resin connects the metal plates and provides additional structural support, enabling a narrower bezel design that maintains both aesthetic quality and sufficient structural strength.
3Strength
If additional connection parts are added to the top case to strengthen it, then the structural strength improves, but the device complexity increases
Solution Approach 1:
The connection function is merged with the resin material that bonds the metal plates together. The resin serves both as an adhesive to join the plates and as a structural element that contributes to the overall strength, eliminating the need for separate connection parts and reducing device complexity.
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 material costs, enhances the structural strength of the display device, prevents foreign substances from entering, and provides a bezel-free design that focuses user attention on the display area, while maintaining high protection and aesthetic quality.
Implementation Method 1
a top case 100 which comprises a main frame 102 made of metal and having a patterned surface treatment and a sub frame 101 made of thermoplastic resin and combined with the main frame 102
Data Source
Figure 1
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AI summary
A display device includes a display panel (200) having a bezel area (200b) formed around a display area (200a); a backlight unit (300) disposed on a rear side of the display panel (200); a supporting member (402) to support the display panel (200) and the backlight unit (300); and a top case (100) having an injection molded sub frame (101) which is disposed on the bezel area and combined with a main frame (102), wherein the main frame (102) is formed of metal plates which are joint by the sub frame, and the main frame (102) is combined with the supporting member (402).