Illumination Frame-Cap Interlock for Clear Zone Boundaries
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Solution Overview
Problem
Existing illumination devices suffer from non-uniform illumination and blurred zone boundaries due to loose fitting between the light-diffusing film and frame, leading to reduced pixel quality and increased manufacturing complexity and costs.
Innovation Solution
The illumination device incorporates protrusions on the cap and corresponding recesses on the frame, ensuring a tight fit of the light-diffusing film, which maintains uniform illumination and enhances assembly reliability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive strip or glue is used to adhere the light-diffusing film to the frame, then the film can be fixed to the frame, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent extracts the adhesive material from the system by replacing glue/adhesive strips with mechanical interlocking features (recesses and protrusions). The light-diffusing film is fixed to the frame through geometric engagement rather than chemical bonding, eliminating the need for additional adhesive materials and simplifying the manufacturing process while maintaining reliable fixation.
Solution Approach 2:
The patent introduces recesses in the frame walls and corresponding protrusions on the light-diffusing film as intermediary mechanical features. These geometric intermediaries provide the fixation function previously achieved by adhesive materials, enabling reliable attachment through shape complementarity rather than chemical bonding.
2Reliability
If adhesive strip or glue is used to adhere the light-diffusing film, then the film can be fixed, but additional materials and quality control requirements increase manufacturing costs
Solution Approach 1:
The patent removes adhesive materials (glue, adhesive strips) from the manufacturing process and replaces them with integral recesses and protrusions formed as part of the frame and film structures. This eliminates quality control requirements for adhesive application, temperature regimens, and humidity control, significantly simplifying manufacturing while ensuring reliable fixation.
Solution Approach 2:
The recesses and protrusions are designed to self-align and self-fixate the light-diffusing film to the frame during assembly. The geometric features automatically guide proper positioning and provide inherent fixation without requiring external adhesive materials or complex quality control procedures, making the manufacturing process more straightforward and reliable.
3Ease of manufacture
If the light-diffusing film is loosely fitted to the frame, then assembly is simpler, but light mixes between adjacent isolated zones reducing image clarity
Solution Approach 1:
The patent introduces recesses in the frame walls and corresponding protrusions on the light-diffusing film as intermediary mechanical features. These geometric intermediaries provide the fixation function previously achieved by adhesive materials, enabling reliable attachment through shape complementarity rather than chemical bonding.
Solution Approach 2:
The patent applies local quality by creating specific recesses at strategic locations on the frame walls and corresponding protrusions at matching locations on the light-diffusing film. This localized geometric engagement provides precise fixation at critical points, ensuring the film remains tightly fitted to prevent light mixing between zones while maintaining overall assembly simplicity.
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 achieves high clarity and uniformity of displayed images by preventing light mixing between zones, simplifying assembly, and reducing material consumption while maintaining aesthetic appeal.
Implementation Method 1
A thin light-diffusing film covers a top portion of the frame. Said film is intended to make the light of each isolated zone more uniform
Implementation Method 2
an inner side of the cap is provided with protrusions, the film is provided with holes that correspond to the protrusions, the frame walls, from their top edges, are provided with recesses which correspond to the protrusions, and the protrusions extend through the holes provided in the film to the recesses provided in the frame walls
Data Source
AI summary
The illumination device includes a frame having opaque walls forming at least two mutually isolated zones, at least one lighting source mounted in at least one of the isolated zones, a light-diffusing film covering a top portion of the frame and including holes, and an at least translucent cap covering the light-diffusing film having an inner side provided with protrusions. The protrusions extend through the holes provided in the film to recesses provided in the frame walls, and at least a part of the protrusions is coupled to the frame walls.