Reflective Sheet Layout for Odd-LED Display Backlight Assembly
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Solution Overview
Problem
Existing display devices face challenges in efficiently manufacturing reflective sheets due to the need for separate molds for each sheet, especially when the number of light sources on the substrate is odd, and there is a difficulty in preventing reflective sheets from lifting or peeling off during assembly.
Innovation Solution
A display device structure that allows common use of reflective sheets by employing first and second reflective sheets with specific hole configurations and protruding portions, enabling them to be manufactured using a single mold even when the number of light sources is odd, and preventing overlap or lifting during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate molds are used for each reflective sheet, then each sheet can be precisely manufactured, but the device complexity and manufacturing cost increase
Solution Approach 1:
The reflective sheet is divided into multiple parts (first reflective sheet and second reflective sheet) that can be manufactured using a single mold. Each part corresponds to a specific region with light sources, allowing the mold to be reused for manufacturing multiple reflective sheets by positioning different regions of the same mold.
Solution Approach 2:
A single mold is designed to manufacture multiple reflective sheets (first and second reflective sheets) by incorporating multiple regions or cavities within the mold structure. This universal mold can produce different reflective sheet parts through different positioning or configuration, eliminating the need for separate dedicated molds for each sheet.
2Area of stationary object
If reflective sheets are positioned closely together, then the display area is maximized, but the sheets may lift or peel from each other during assembly
Solution Approach 1:
The first and second reflective sheets are designed with overlapping regions where one sheet partially covers or nests over the other. This nested configuration provides mechanical interlocking and adhesive bonding area, preventing the sheets from lifting or peeling while maintaining close positioning to maximize display area.
3Adaptability or versatility
If the number of light sources is odd, then the lighting configuration is flexible, but a single mold cannot be used for all reflective sheets
Solution Approach 1:
The mold design incorporates asymmetric regions or cavities that can accommodate an odd number of light sources. By designing the mold with asymmetric positioning capabilities, a single mold can produce reflective sheets with varying light source configurations, including odd numbers, without requiring multiple specialized molds for different configurations.
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 structure facilitates efficient manufacturing of reflective sheets with reduced mold requirements and prevents lifting or peeling, enhancing assembly stability and consistency.
Implementation Method 1
A reflective sheet covers an LED substrate and reflects light from the LED toward a display panel
Data Source
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AI summary
A display device including a display panel; a frame disposed at a rear of the display panel; a substrate disposed between the display panel and the frame, the substrate being coupled to the frame; light sources disposed on the substrate; and a reflective sheet covering the substrate and having holes, the holes corresponding to the light sources, wherein the reflective sheet comprises: a first reflective sheet including first holes and a protruding portion protruding from one side of the first reflective sheet including some of the first holes; a second reflective sheet having second holes; a third reflective sheet having third holes; and a fourth reflective sheet having fourth holes and having a same shape as the third reflective sheet, wherein the second reflective sheet is identical to the first reflective sheet except for the protruding portion.