Extruded Display Frame with Acute-Angle Sidewalls

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Solution Overview

Problem

Conventional display device frames, particularly for large screens, face increased manufacturing costs and weight due to the use of metal chassis formed by press processes, which compromise the structural integrity and rigidity.

Innovation Solution

A lightweight frame for display devices is designed using extruded cover members with specific geometries, including support and sidewall portions that form acute angles, providing enhanced rigidity and hardness, and incorporating a reflection sheet for improved heat dissipation and structural support, while reducing deflection risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal chassis is used for large screen display devices, then structural integrity and rigidity are improved, but weight and manufacturing cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent employs composite material construction by combining metal support portions with plastic sidewall portions in the cover member. This composite structure achieves the necessary structural integrity and rigidity while significantly reducing the overall weight compared to conventional all-metal chassis designs for large screen display devices.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The cover member is segmented into distinct functional portions: metal support portions for structural strength and plastic sidewall portions for weight reduction and aesthetic coverage. This segmentation allows each material to be optimized for its specific function, resolving the contradiction between strength and weight.

Inventive Principle:

Principle #1Segmentation

2Strength

If a metal chassis is used for large screen display devices, then structural integrity is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

By using composite materials (metal + plastic) instead of solid metal, the patent reduces material costs and manufacturing complexity. The plastic sidewall portions can be molded and attached to metal support portions, which is more cost-effective than forming large metal chassis structures through press processes.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent substitutes expensive metal components with cheaper plastic components for the sidewall portions, which do not require the same structural strength as the support portions. This substitution significantly reduces manufacturing cost while maintaining adequate structural integrity through the metal support portions.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If conventional press process is used to form chassis, then manufacturing is simplified, but weight and cost increase

Engineering Contradiction:

Improvemanufacturing processVSAvoidweight

Core Design Contradiction:

Ease of manufactureVSWeight of stationary object

Solution Approach 1:

The patent replaces the conventional press-formed metal chassis with a composite structure combining metal support portions and plastic sidewall portions. This new manufacturing approach uses extrusion for metal portions and molding for plastic portions, which are then assembled, achieving weight reduction while maintaining manufacturing feasibility.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The chassis is segmented into metal support portions and plastic sidewall portions that can be manufactured separately using different processes (extrusion and molding), then assembled. This segmentation enables weight reduction through material optimization while keeping the manufacturing process manageable through modular assembly.

Inventive Principle:

Principle #1Segmentation

4Weight of stationary object

If lightweight materials are used to reduce weight, then weight decreases, but rigidity and hardness decrease

Engineering Contradiction:

ImproveweightVSAvoidrigidity

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent uses composite materials where metal support portions provide the necessary rigidity and hardness, while plastic sidewall portions provide weight reduction. The metal components are strategically positioned to bear structural loads, ensuring rigidity is maintained despite the use of lighter plastic materials for the sidewalls.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different portions of the cover member have different material qualities optimized for their specific functions: metal support portions have high rigidity and hardness where structural strength is needed, while plastic sidewall portions have lower density for weight reduction where aesthetic coverage is prioritized. This local quality differentiation resolves the contradiction between weight and rigidity.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9563078B2Frame for display device and display device having the same

Publication Date: 2017.02.07 SAMSUNG DISPLAY CO LTD

AI summary

A frame for display device includes a plurality of cover members. Each of the cover members includes a support portion including a supporting body extending in a first direction, and a first extending portion extending from the supporting body in a second direction substantially perpendicular to the first direction, the first extending portion supporting an edge portion of a support plate of the display device, and a sidewall portion extending from the support portion to form a predetermined acute angle with respect to the support portion and covering a side of the display device.