Flat Panel Display Assembly Using Unidirectional Front Frame Positioning
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Solution Overview
Problem
The conventional assembly process of flat panel displays is inefficient, requiring multiple stages and frequent turning of the display, which increases manpower needs, production time, and costs, especially as displays grow in size.
Innovation Solution
A method and structure for assembling flat panel displays where all components are integrated and assembled along a single direction, using a front frame with positioning members to mount and fix the panel unit, optical films, and a backlight unit sequentially, eliminating the need for repeated display turning and reducing the number of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conventional three-stage assembly process is used with repeated turning, then each component can be assembled in its designated stage, but the production time increases and productivity decreases
Solution Approach 1:
The patent merges the three separate assembly stages (backlight unit assembly, LCM unit assembly, and flat panel display assembly) into a single integrated assembly process. All components including the backlight unit, optical films, panel unit, and back cover are assembled in one continuous operation without requiring multiple stage transitions, thereby eliminating production bottlenecks and improving overall productivity.
Solution Approach 2:
The patent applies preliminary action by pre-assembling the backlight unit with the back cover before the main assembly process. This preliminary preparation allows the backlight unit to be quickly integrated into the front frame during the single-direction assembly, reducing overall assembly time and improving efficiency without compromising the organized assembly approach.
2Ease of manufacture
If the flat panel display is turned over repeatedly during assembly, then different components can be accessed and assembled, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent inverts the conventional assembly approach by assembling all components in a single direction rather than turning the display repeatedly. The front frame serves as the base structure, and all other components (backlight unit, optical films, panel unit, back cover) are assembled in one direction relative to this base, eliminating the need for repeated turning and significantly reducing assembly time.
Solution Approach 2:
The patent transitions from a multi-directional assembly process (requiring repeated turning) to a unidirectional assembly process. By establishing the front frame as a fixed reference and assembling all components along a single axis, the patent simplifies the assembly geometry and eliminates the time loss associated with repositioning and turning the display multiple times.
3Manufacturing precision
If more positioning structures are added to the front frame for positioning the liquid crystal cell, then the liquid crystal cell can be accurately positioned, but the device complexity increases
Solution Approach 1:
The patent applies universality by designing the front frame with positioning structures that serve multiple functions. The same positioning structures on the front frame are used to position both the liquid crystal cell and the backlight unit, eliminating the need for separate positioning mechanisms for each component. This multi-functional approach maintains high positioning precision while reducing overall structural complexity.
4Productivity
If the assembly process is integrated into a single direction, then production efficiency improves and production costs decrease, but the assembly process requires a different approach from conventional methods
Solution Approach 1:
The patent applies segmentation by dividing the integrated assembly process into distinct sequential steps, each handling specific components. The assembly process is segmented into: (1) mounting the panel unit to the front frame, (2) fixing optical films to the front frame, and (3) fixing the backlight unit with back cover to the front frame. This segmentation makes the innovative unidirectional process easier to implement and understand while maintaining high production efficiency.
Data Source
AI summary
A front frame of a flat panel display having positioning structure allows a LCD cell to be positioned and mounted thereon along an assembly direction. A restraining frame may be further incorporated for positioning and spacing purposes for each component of the display. Optical films, a light guide component, a backlight unit, and a reflector of the flat panel display are then mounted in a row along the assembly direction on the restraining frame or the front frame, where the backlight unit and/or the reflector may be fixed to a back cover of the backlight module in advance. Finally, a speaker, wiring of the display, circuit boards, and a board cover are assembled to the front frame and the back cover.