Reflecting Sheet Reinforcing Layer Adsorption Prevention
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Solution Overview
Problem
Existing reflecting sheets for backlight units in LCD devices suffer from adsorption issues with light guide plates, leading to image stains and reduced brightness uniformity, and their production methods have limitations that require additional equipment investments.
Innovation Solution
A reflecting sheet is fabricated by dividing a base sheet into upper and lower division sheets and forming a reinforcing layer on at least one of these sheets, which includes a fine foam reflecting layer and a surface layer, to prevent adsorption and improve durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the reflecting sheet is made thinner to improve light transmission and brightness uniformity, then the reflective performance is improved, but the mechanical strength and durability deteriorate
Solution Approach 1:
The patent applies composite materials by combining the reflecting layer with a reinforcing layer made of different materials (such as polyethylene terephthalate or polypropylene). This composite structure allows the reflecting sheet to maintain thin thickness for good light transmission while the reinforcing layer provides the necessary mechanical strength and durability to prevent breakage during handling and installation.
2Productivity
If the base sheet is divided into upper and lower division sheets to improve production efficiency, then the productivity increases, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the base sheet into upper and lower division sheets during the manufacturing process. This allows simultaneous production of multiple reflecting sheets from a single base sheet, effectively doubling production efficiency. The division is performed at a stage where the material is still manageable, and the subsequent forming of reinforcing layers on each division sheet follows standard manufacturing procedures, keeping the added complexity manageable.
3Reliability
If a reinforcing layer is formed on the division sheets to prevent adsorption with light guide plates, then the reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the reinforcing layer on the division sheets during the manufacturing process, before the reflecting sheet is installed in the display device. This preliminary formation of the reinforcing layer prevents adsorption issues with light guide plates during operation, while the process is integrated into existing manufacturing steps, minimizing the increase in manufacturing complexity.
4Illumination intensity
If the reflecting sheet thickness is reduced to improve brightness uniformity, then the illumination intensity improves, but the resistance to damage from light guide plates deteriorates
Solution Approach 1:
The patent uses composite materials to create a multi-layer structure where a thin reflecting layer provides good brightness uniformity and light transmission, while an added reinforcing layer made of durable materials protects against damage from light guide plates. This composite approach allows both requirements to be satisfied simultaneously - the thin reflecting layer ensures optical performance while the reinforcing layer provides mechanical protection.
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 approach enhances brightness uniformity, prevents damage from light guide plates, and significantly increases production efficiency by reducing the thickness of the reflecting sheet while maintaining or improving its reflective performance.
Implementation Method 1
the reflecting sheet 22 disposed over the bottom frame 50 is integrated with the lamp housing 30 as one body... the reflecting sheet that is disposed under the light guide plate to reflect the incident light from the light source
Data Source
AI summary
A method of fabricating a reflecting sheet includes: providing a base sheet including a reflecting layer, an upper surface layer over the reflecting layer and a lower surface layer under the reflecting layer, the reflecting layer including a fine foam; dividing the base sheet into upper and lower division sheets; and forming a reinforcing layer on each of the upper and lower division sheets to constitute the reflecting sheet.