Reinforced Backlight Substrate Layout for Low-Cost Rigidity
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Solution Overview
Problem
Existing display devices face challenges in reducing production costs while maintaining rigidity, particularly in backlight units, which are crucial components of displays like LCDs and OLEDs.
Innovation Solution
A backlight unit design featuring a first substrate with LEDs, a reinforcement substrate crossing the second substrates, guide holes, screw holes, and adhesive tapes to secure the components, enhancing rigidity and assembly convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional backlight substrate structure is used, then the structure is simple and easy to manufacture, but the rigidity is insufficient and sagging occurs
Solution Approach 1:
The backlight substrate is divided into a first substrate and a separate reinforcement substrate. The first substrate supports the LEDs and optical components, while the reinforcement substrate provides additional rigidity and prevents sagging. This segmentation allows each substrate to be optimized for its specific function without compromising the other.
Solution Approach 2:
The invention uses a composite structure combining two different substrates (first substrate and reinforcement substrate) with distinct functional roles. The first substrate is optimized for component mounting and optical performance, while the reinforcement substrate is optimized for mechanical strength and rigidity, creating a composite system that achieves both requirements.
2Ease of manufacture
If production costs are reduced by simplifying the backlight unit, then manufacturing becomes cheaper, but assembly alignment and fastening become difficult
Solution Approach 1:
Guide holes are pre-formed in both the first substrate and the reinforcement substrate at precisely calculated positions before assembly. These guide holes enable automatic alignment during the assembly process, ensuring that screws and fastening elements are correctly positioned without requiring complex alignment procedures or additional adjustment steps.
Solution Approach 2:
The guide holes act as intermediary alignment features that facilitate the connection between the first substrate and the reinforcement substrate. By providing pre-defined alignment paths, the guide holes simplify the fastening process and ensure accurate positioning of mounting elements, making assembly easier while maintaining structural integrity.
3Ease of manufacture
If the number of components is reduced to lower production costs, then manufacturing becomes more economical, but rigidity and structural stability are compromised
Solution Approach 1:
Instead of using a single complex substrate that would require more material and processing, the structure is segmented into two simpler substrates (first substrate and reinforcement substrate) that work together. This segmentation reduces manufacturing complexity and costs while the combination of the two substrates provides the necessary structural stability and rigidity.
Data Source
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AI summary
Abstract: A backlight unit comprises: a backlight substrate including a first substrate which extends in a first direction and a plurality of second substrates which extend from the first substrate in a second direction perpendicular to the first direction and are spaced apart from each other in the first direction; a plurality of light-emitting elements arranged at the front surface of each of the second substrates to be spaced apart from each other in the second direction; and a reinforcement substrate intersecting the plurality of second substrates and extending in the first direction. The backlight unit can not only reduce unit production cost but can also ensure rigidity.