Liquid Crystal Display Optical Sheet Spacer Design
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Solution Overview
Problem
Conventional liquid crystal display devices face limitations in reducing external dimensions without risking damage to glass substrates due to the potential for direct contact between metal frames and glass substrates, which can lead to cracking.
Innovation Solution
Incorporating a thin optical sheet as a spacer between the glass substrates and the metal frame to prevent direct contact and allow for reduced external dimensions while maintaining screen size and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the resin mold is excluded to reduce external dimensions, then the exterior size is reduced, but the glass substrate may come into direct contact with the metal frame causing cracks
Solution Approach 1:
The patent introduces an optical sheet as an intermediary component between the glass substrate and the metal frame. This optical sheet serves as a mediator that prevents direct contact between the glass substrate and the metal frame, thereby eliminating the risk of cracks while still allowing for reduced external dimensions. The optical sheet is positioned in the spacer region and provides the necessary separation without requiring a thick resin mold.
Solution Approach 2:
The optical sheet performs multiple functions: it serves as both an optical component for the display device and as a structural spacer that prevents contact between the glass substrate and the metal frame. By making the optical sheet multi-functional, the patent eliminates the need for a separate protective spacer component, thereby reducing overall device thickness and external dimensions while maintaining reliability.
2Length of stationary object
If the thickness of the resin mold is reduced to minimize external dimensions, then the exterior becomes more compact, but the glass substrate is at risk of cracking due to contact with the metal frame
Solution Approach 1:
The optical sheet acts as a mediator that provides the necessary separation between the glass substrate and the metal frame. Instead of relying on a thick resin mold for protection, the optical sheet is positioned in the spacer region to provide mechanical separation, thereby protecting the glass substrate while allowing the resin mold thickness to be minimized for a more compact exterior.
Solution Approach 2:
The patent extracts the protective spacer function from the resin mold structure and assigns it to the optical sheet. By taking out the protective function from the mold and assigning it to an existing optical component, the patent allows the resin mold to be made thinner while maintaining the necessary protection for the glass substrate.
3Productivity
If injection molding is used to manufacture the resin mold, then production efficiency is improved, but the minimum thickness is limited to 0.45 mm preventing further exterior reduction
Solution Approach 1:
The optical sheet serves as a mediator that provides the necessary structural separation function, allowing the resin mold to be made thinner than the 0.45 mm injection molding limit. By positioning the optical sheet in the spacer region, the patent enables the use of thinner resin molds that would otherwise be structurally inadequate, thereby reducing external dimensions while maintaining manufacturing efficiency through injection molding.
Data Source
AI summary
An object of the present invention is to reduce the exterior of a display device while retaining a display screen at a certain size. A liquid crystal display panel including a TFT substrate formed with a glass substrate and a color filter substrate is stored in a frame made of a metal. In order to avoid the direct contact between the glass substrate and the frame made of a metal, part of an optical sheet included in a backlight disposed behind the liquid crystal display panel is extended to lie between the liquid crystal display panel and the frame, and is regarded as a spacer. Since the thickness of the optical sheet is as small as 0.06 mm, the spacer hardly affects the external dimensions of a display device. Consequently, while a crack of the glass substrate is prevented, the exterior of the display device can be reduced.