Reflective Sheet Layout for Odd-LED Display Backlights
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Solution Overview
Problem
Existing display devices require separate molds for each reflective sheet, which is inefficient and can lead to issues like one reflective sheet being lifted from another, especially when the number of light sources on the substrate is odd.
Innovation Solution
A display device design that uses a common mold for reflective sheets, with overlapping sheets and protruding portions to prevent lifting, and includes reflective sheets with holes matching the number of light sources, allowing for even or odd numbers of light sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate molds are used for each reflective sheet, then each sheet can be customized, but manufacturing efficiency decreases and costs increase
Solution Approach 1:
The reflective sheet is divided into multiple sections, each corresponding to a specific light source region. This segmentation allows a single mold to produce multiple reflective sheet sections in one manufacturing cycle, improving efficiency while maintaining the ability to customize each section's properties
Solution Approach 2:
A universal mold design is implemented that can accommodate different light source configurations (odd or even numbers) by adjusting the positioning fixtures. The mold includes standardized features that allow it to serve multiple purposes across different product variants, reducing the need for dedicated molds for each configuration
2Area of stationary object
If reflective sheets are placed adjacent to each other, then coverage is maximized, but sheets may lift from each other causing defects
Solution Approach 1:
The reflective sheets are designed with overlapping edges where one sheet partially covers another, creating a nested arrangement. This overlapping structure prevents lifting by distributing mechanical stresses and creating inter-sheet mechanical interlocking, while the nested configuration maximizes the effective reflective coverage area
Solution Approach 2:
Adhesive material is pre-applied to the overlapping edge regions of the reflective sheets before assembly. This preliminary bonding action ensures that when sheets are positioned adjacent to each other, they are immediately secured against lifting forces, maintaining reliability while maximizing coverage
3Adaptability or versatility
If the number of light sources is odd, then design flexibility is maintained, but traditional molding methods require separate molds
Solution Approach 1:
The mold incorporates adjustable and reconfigurable components, including movable positioning fixtures and adaptable cavity configurations. This dynamic mold design allows it to accommodate odd numbers of light sources by adjusting the positioning of internal features, eliminating the need for separate dedicated molds while maintaining design flexibility for various light source arrangements
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
Enables efficient manufacturing of reflective sheets with common molds, preventing sheet lifting and ensuring uniform light reflection, even with odd numbers of light sources.
Implementation Method 1
a reflective sheet covering the substrate and having holes equal in number to the light sources
Data Source
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.