Reflector Sheet Aperture Segmentation for Thermal Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current direct-lit backlight modules experience uneven light reflection due to deformation of the reflector sheet caused by thermal expansion of LED devices, as the reflector sheet lacks a mechanism to release deformation stress.
Innovation Solution
The reflector sheet incorporates a combination of first and second apertures, where first apertures fix the LED devices and second apertures create a gap to accommodate thermal expansion, preventing deformation and ensuring even light reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the reflector sheet is tightly fixed to the back plate with apertures matching the LED device size, then the structural stability and light reflection uniformity are improved, but the reflector sheet cannot accommodate thermal expansion of LED devices, causing deformation and uneven light reflection
Solution Approach 1:
The aperture pattern is segmented into multiple functional zones: first apertures for LED mounting, second apertures for stress relief, and third apertures for additional expansion space. This segmentation allows different regions of the reflector sheet to serve different purposes, simultaneously achieving structural stability and thermal expansion accommodation
Solution Approach 2:
Different regions of the reflector sheet are given different properties through the selective distribution of aperture types. Areas with LED devices have mounting apertures for stability, while other areas have stress relief apertures for expansion accommodation, creating local quality variations that resolve the global contradiction
2Manufacturing precision
If the aperture size is reduced to match the LED device precisely, then the light reflection uniformity is improved, but the deformation stress from thermal expansion has nowhere to release, causing reflector sheet deformation
Solution Approach 1:
The aperture system is segmented into precision-mounted first apertures for LED positioning and larger second/third apertures for stress relief. This segmentation allows the mounted LEDs to have precise aperture matching for good light reflection, while other apertures provide the necessary expansion space
Solution Approach 2:
The second and third apertures act as intermediary elements that mediate between the precisely fitted first apertures and the thermal expansion forces. These intermediate apertures provide release paths for deformation stress, protecting the precision-mounted LEDs from stress-induced misalignment
3Shape
If the reflector sheet is made rigid to maintain shape, then the light reflection uniformity is improved, but it cannot accommodate the expansion of LED devices during prolonged heating, leading to deformation
Solution Approach 1:
The reflector sheet structure is segmented into rigid zones (around first apertures with LEDs) and flexible zones (around second and third apertures). The rigid zones maintain shape for uniform light reflection, while the flexible zones with additional apertures accommodate thermal expansion through controlled deformation
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 design effectively prevents uneven light reflection by allowing the reflector sheet to release deformation stress, thereby enhancing display quality and maintaining consistent light output.
Implementation Method 1
the prolonged heating of the LED device may lead to expansion of part of the reflector sheet 20 around the LED device
Data Source
AI summary
A reflector sheet, a backlight module and a display apparatus, which relate to the display technical field, are provided. They can reserve a space for deformation during thermal expansion of the reflector sheet and prevent the reflector sheet from being deformed, thereby avoiding uneven light. The reflector sheet comprises a reflector sheet body and apertures located in the reflector sheet body and configured for allowing a luminous body to pass therethrough, the apertures comprising first apertures and second apertures, wherein each of the first apertures is configured for relatively fixing a luminous body passing therethrough and the reflector sheet body, and each of the second apertures is configured for reserving a gap between a luminous body passing therethrough and the reflector sheet body. Also disclosed is use of the reflector sheet for manufacturing a display apparatus.