Reflective Structure With Concave Coating For Panel Lamps
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Solution Overview
Problem
Existing reflection structures in backlight modules and LED panel lamps are too heavy and thick, making them difficult to assemble and resulting in low assembly efficiency and increased product weight.
Innovation Solution
A reflection structure comprising a reflection layer, an enhancement layer, and a light shielding layer, where the reflection layer includes a substrate with a coating layer of polyethylene terephthalate particles and an acrylate adhesive, and the enhancement layer is made of flexible glass or polypropylene terephthalate, providing a concave and convex surface for anti-scratch and anti-adsorption properties, while the light shielding layer offers excellent light-shielding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal back plate and foam layer are used in the reflection structure, then the structural stability and heat resistance are improved, but the weight and thickness of the product significantly increase
Solution Approach 1:
The patent replaces the rigid metal back plate and foam layer with a flexible reflection film that has heat-resistant and structurally stable properties. This thin film structure maintains the necessary structural stability and heat resistance while dramatically reducing the weight and thickness of the overall product.
Solution Approach 2:
The reflection film is designed as a composite structure with multiple functional layers including a base layer, reflective layer, and protective layer. This composite material approach allows the single film to simultaneously provide structural stability, heat resistance, and light reflection functionality that previously required multiple separate components.
2Strength
If a metal back plate with large thickness is used, then the structural strength is improved, but the assembly efficiency decreases and rework becomes troublesome
Solution Approach 1:
The flexible reflection film replaces the thick metal back plate, enabling the structure to maintain sufficient strength while being much thinner and more flexible. This allows for significantly improved assembly efficiency as the thin film can be easily handled, positioned, and attached without requiring heavy fastening hardware or complex assembly procedures.
Solution Approach 2:
The patent combines multiple functions (structural support, heat resistance, light reflection) into a single integrated reflection film component. This merging eliminates the need for separate metal back plates, foam layers, and fastening hardware, thereby simplifying the assembly process and improving productivity.
3Weight of moving object
If the reflection structure is made thinner and lighter, then the product weight and thickness are reduced, but the stiffness and resistance to collapse decrease
Solution Approach 1:
The reflection film employs a composite material structure with a base layer providing mechanical strength and stiffness, a reflective layer for light reflection, and a protective layer for durability. This composite design ensures that even though the overall structure is thin and light, it maintains sufficient stiffness and resistance to collapse through the synergistic properties of the composite layers.
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 structure is lighter, thinner, and more assembly-efficient, with improved stiffness and light-shielding properties, reducing the risk of collapse and light leakage, and enhancing brightness and assembly efficiency.
Implementation Method 1
the plurality of coating particles are disposed on the substrate layer by the adhesive in order to form the coating layer, resulting in the coating layer has a concave and convex surface
Implementation Method 2
the plurality of coating particles are disposed on the substrate layer by the adhesive in order to form the coating layer
Implementation Method 3
A reflection structure comprising a reflection layer, an enhancement layer and a light shielding layer stacked together
Data Source
Figure 1~3
AI summary
The present disclosure provides a reflection structure and the application thereof in a panel lamp and display. The reflection structure can include a reflection layer, an enhancement layer and a light shielding layer stacked together. The reflection layer can include a substrate layer and a coating layer on at least one surface of the substrate layer. The coating layer can include a plurality of coating particles and an adhesive. And the plurality of coating particles can be disposed on the at least one surface of the substrate layer by the adhesive in order to form the coating layer, resulting in the coating layer has a concave and convex surface.