Reflective Sheet Dot-Cut Pattern for LCD Brightness Uniformity
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Solution Overview
Problem
Existing reflective sheets for liquid crystal display devices face challenges in maintaining uniform luminance, leading to bright lines and spots, which increases manufacturing costs and reduces efficiency.
Innovation Solution
A reflective sheet with a bottom part and lateral part, featuring a half-cut pattern and dot-cut patterns formed by a single punching process, is designed to control light reflection and prevent bright lines and spots, improving luminance uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate processes are used to form the half-cut pattern and dot pattern on the reflective sheet, then the manufacturing precision of each pattern can be controlled, but the manufacturing complexity and time increase
Solution Approach 1:
The patent combines the formation of the half-cut pattern and dot pattern into a single punching process. The punching tool is designed with multiple cutting edges that simultaneously create both patterns in one operation, eliminating the need for separate processing steps and reducing manufacturing complexity while maintaining precision
Solution Approach 2:
The punching tool is designed to perform multiple functions: it creates both the half-cut pattern for light extraction and the dot pattern for luminance uniformity control. This multi-functional tooling approach simplifies the manufacturing system by consolidating what would otherwise require separate specialized processes
2Productivity
If a single punching process is used to form both half-cut and dot patterns, then manufacturing efficiency increases, but the manufacturing precision of individual patterns may be compromised
Solution Approach 1:
The patent merges multiple pattern formation operations into a single punching process, achieving high manufacturing efficiency. The tool design ensures that both the half-cut and dot patterns are formed simultaneously with consistent precision through proper tooling geometry and material positioning
3Ease of manufacture
If the dot pattern is formed by inkjet printing instead of punching, then the manufacturing process is simpler, but the manufacturing cost increases due to material waste and additional processing steps
Solution Approach 1:
The patent replaces the chemical/thermal process of inkjet printing with a mechanical punching process. This substitution eliminates material waste associated with ink consumption and drying, while also removing the need for additional processing steps such as curing, thereby reducing both environmental impact and manufacturing cost
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 enhances light uniformity, improves display quality, reduces manufacturing costs, and increases efficiency by allowing a single process to form the necessary patterns on the reflective sheet.
Implementation Method 1
a reflective sheet with a dot-cut pattern for preventing both bright line and bright spot
Data Source
AI summary
A reflective sheet with a dot-cut pattern for preventing both bright line and bright spot, and a method of manufacturing the same, is provided. The reflective sheet and method of manufacturing the same may be capable of reducing a manufacturing cost and also improving a manufacturing efficiency. The reflective sheet may include a bottom part including a hole for exposing a light source, the bottom part provided on a bottom surface of a cover bottom; a lateral part extending from the bottom part, the lateral part provided at a lateral surface of the cover bottom; a half-cut pattern formed in the boundary between the bottom part and the lateral part; and a plurality of dot-cut patterns formed at the lateral part.