Integrated Lens Supports for Display Optical Distance
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Solution Overview
Problem
Display devices with direct LED backlight units face challenges in maintaining the optical distance between the optical lens and the diffuser plate, which affects light diffusivity and uniformity, leading to increased manufacturing costs and potential degradation of optical properties due to heat-induced deformation of the diffuser plate.
Innovation Solution
The integration of supports within the optical lens, such as the first, second, and third supports, maintains a consistent optical distance between the optical lens and the diffuser plate, preventing deformation and enhancing light diffusion properties while simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the optical distance between the optical lens and the diffuser plate is maintained to retain optical lens characteristics, then light diffusivity is improved, but device complexity increases due to the need for additional support structures
Solution Approach 1:
The support structures are integrated directly into the optical lens body, merging two previously separate components (lens and supports) into a single unified structure. This eliminates the need for separate support elements while maintaining the required optical distance, thereby reducing device complexity without compromising light diffusivity
Solution Approach 2:
The optical lens is designed to serve multiple functions: it acts as both the optical element for light diffusion and the structural support for maintaining optical distance. By making the lens multi-functional, the patent eliminates the need for dedicated support structures, resolving the contradiction between maintaining optical properties and reducing device complexity
2Manufacturing precision
If separate support structures are used to maintain optical distance, then manufacturing precision can be achieved, but manufacturing costs increase
Solution Approach 1:
By combining the support function into the lens manufacturing process itself, the patent eliminates the need for separate support components and their associated assembly steps. This integration simplifies the manufacturing process and reduces costs while maintaining precise optical distance through the lens's own structural design
Solution Approach 2:
The lens is designed with integrated support portions that are strategically positioned to maintain optical distance only where needed, rather than using a complete separate support structure. This segmented approach to support integration reduces material usage and manufacturing complexity while achieving the required precision
3Length of stationary object
If the diffuser plate is positioned close to the optical lens to reduce device thickness, then device compactness is improved, but heat-induced deformation occurs affecting optical properties
Solution Approach 1:
The integrated support structures within the lens provide continuous thermal and mechanical stability to the diffuser plate, preventing heat-induced deformation even when positioned close to the lens. This merger of support functionality into the lens allows compact positioning without sacrificing optical property stability
4Reliability
If additional support structures are added to maintain optical distance, then optical property stability is improved, but light uniformity deteriorates due to support interference
Solution Approach 1:
The support structures are designed with specific local characteristics - they are positioned and shaped to provide necessary support only in critical areas while minimizing their presence in light paths. This localized support approach maintains optical property stability without causing significant interference with light uniformity
Solution Approach 2:
The integrated support portions act as intermediaries between the lens and diffuser plate, providing mechanical stability while being designed to minimize optical interference. Their integration into the lens allows them to serve as mediators that maintain distance without being separate interfering elements
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
This configuration ensures consistent optical properties, improves light uniformity, reduces manufacturing costs, and minimizes interference from supports, thereby enhancing the overall performance and cost-effectiveness of the display device.
Implementation Method 1
an optical lens 110 that emits light from the light source in multiple directions
Implementation Method 2
to emit the light guided in the light guiding lens in a vertical direction
Data Source
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AI summary
Provided is a display device. The display device includes a display panel; a light source configured to emit light toward the display panel; a diffuser plate configured to diffuse incident light and disposed between the light source and the display panel; an optical lens configured to diffuse the light emitted by the light source; and at least one support provided adjacent to an edge of the optical lens and protruding toward the diffuser plate, the optical lens being integrally formed with the at least one support.