Foamed Plastic Reflector Plate Stiffness in Flat Panel Displays
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Solution Overview
Problem
Conventional liquid crystal display devices face issues with high material costs and structural complexity due to unitary back frames, and conventional reflector plates have insufficient strength, leading to potential collapse and compromised optic quality.
Innovation Solution
A flat panel display device and stereoscopic display device design featuring a back frame composed of multiple assembling pieces forming a main frame structure, with a foamed plastic substrate layer and reflection layer for the reflector plate, enhancing stiffness and reducing assembly-related weaknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a unitary back frame is used, then the structure is simple, but the material cost is high and the mold expenditure is high
Solution Approach 1:
The back frame is divided into multiple assembling pieces (first back frame assembling piece, second back frame assembling piece, etc.) that can be separately manufactured and then assembled together. This segmentation allows each piece to be produced using standard-sized molds rather than requiring a large complex mold for the entire unitary back frame, thereby reducing mold expenditure and material costs while maintaining structural integrity.
2Device complexity
If a unitary back frame is used, then the structure is simple, but the mold size is large and the structure is complicated
Solution Approach 1:
By segmenting the back frame into multiple assembling pieces, each piece can be manufactured using smaller, less complex molds. The individual assembling pieces are then joined together through assembly processes, achieving the same overall structural function with significantly reduced mold size and manufacturing complexity for each component.
3Ease of manufacture
If the reflector plate uses conventional substrate material, then the manufacturing is simple, but the strength is insufficient and collapse occurs
Solution Approach 1:
The reflector plate uses a composite structure combining a substrate layer made of foamed plastic material with a reflection layer. The foamed plastic substrate provides enhanced strength and stiffness compared to conventional solid plastic or metal substrates, preventing collapse while maintaining ease of manufacture. The composite structure leverages the beneficial properties of both materials.
Solution Approach 2:
The substrate layer is made of foamed plastic, which is a porous material. This porous structure provides high strength-to-weight ratio and excellent stiffness, preventing collapse of the reflector plate while maintaining ease of manufacture. The foam structure distributes mechanical stresses effectively throughout the substrate.
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 significantly reduces material costs and structural complexity while increasing the stiffness of the reflector plate, minimizing the risk of collapse and improving the overall performance of flat panel and stereoscopic display devices.
Implementation Method 1
the reflector plate comprises a foamed plastic substrate layer and a reflection layer formed on the foamed plastic substrate layer
Implementation Method 2
The reflector plate mainly comprises a reflection layer and a substrate layer
Data Source
AI summary
The present invention provides a flat panel display device, which includes a reflector plate and a back frame that carries the reflector plate, wherein the backlight system includes a reflector plate and a back frame that carries the reflector plate, wherein the back frame includes at least two primary assembling pieces, the at least two primary assembling pieces being joined to form a main frame structure of the back frame; and the reflector plate includes a foamed plastic substrate layer and a reflection layer formed on the foamed plastic substrate layer. The present invention also provides a stereoscopic display device. With the above arrangement, the present invention provides a flat panel display device and a stereoscopic display device that have a substrate layer made of foamed plastics in order to increase the stiffness of the reflector plate, reduce the risk that the reflector plate gets easily collapsing after the assembling of the backlight system, and thereby improve the performance of the flat panel display device and the stereoscopic display device.