Seamless LCD Assembly via Light Transmission Guide
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Solution Overview
Problem
Large-sized liquid crystal display panels face challenges in high production costs and low yield, resulting in visible gaps and luminance uniformity issues when assembled from smaller panels, leading to imperfect image presentation.
Innovation Solution
A method involving a backlight unit, optical film, partitioned structure, liquid crystal panel, and protection layer with micro-structures, along with a locking portion, is used to align and overlap side edges of adjacent panels, ensuring light emission at a specific angle to reduce signal mixing and achieve uniform luminance across the assembled panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple liquid crystal panels are assembled to form a large-sized display, then the display size is increased, but visible gaps appear between adjacent panels causing partitioned image display
Solution Approach 1:
A light transmission guide layer is introduced as an intermediary component between adjacent liquid crystal panels. This layer contains optical fibers or glass tubes that transmit light from the light-emitting panels to the gap areas, effectively filling the visual gaps without requiring physical contact between panels. The intermediary layer resolves the contradiction by maintaining both large display size and seamless visual appearance.
Solution Approach 2:
The refractive index parameter of the light transmission guide layer is carefully controlled to match the surrounding media, enabling efficient light transmission while maintaining visual continuity. By changing and optimizing this optical parameter, the gaps between panels become imperceptible, achieving seamless display effect across the entire large-sized panel.
2Manufacturing precision
If optical fiber or glass tube is used in light transmission guide to eliminate gaps, then seamless display is achieved, but production cost increases and overall thickness increases
Solution Approach 1:
Instead of using expensive optical fibers throughout, the patent applies the light transmission guide layer selectively only in the gap regions between panels. This localized application maintains the seamless display effect where it is most needed while minimizing material costs and overall thickness. The local quality principle allows the system to achieve high performance at critical locations without uniformly increasing complexity everywhere.
3Illumination intensity
If optical correction film is used to filter light from central portion, then luminance uniformity is improved, but overall luminance of the panel degrades
Solution Approach 1:
Instead of filtering light in the traditional optical path, the patent introduces a fourth dimension - time - by using sequentially switched light sources. Different light sources are activated at different times to illuminate different regions, achieving luminance uniformity across the panel without permanently blocking any light. This temporal dimension allows the system to maintain high overall luminance while achieving uniformity.
4Ease of operation
If light transmission guide does not match pixels appropriately, then mechanical tolerance is exceeded, but color and gray level distortion occurs
Solution Approach 1:
The light transmission guide layer is segmented into multiple independent regions, each corresponding to specific pixel areas. This segmentation allows each segment to be independently aligned and adjusted, accommodating mechanical tolerances in assembly. By dividing the system into manageable segments rather than requiring perfect alignment of the entire layer, the patent achieves both ease of assembly and color accuracy.
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 approach results in a visually seamless and high-quality large-sized display with reduced production costs, addressing the issues of gap visibility and luminance uniformity, while maintaining image integrity and reducing mechanical tolerance-related distortions.
Implementation Method 1
protection layer having micro-structures... ensuring light emission at a specific angle to reduce signal mixing
Implementation Method 2
optical film... ensuring light emission at a specific angle to reduce signal mixing and achieve uniform luminance
Data Source
AI summary
A seamless display manufacturing method includes fixing a light emitting source in a backlight module; fixing an optical film on the light emitting source; placing a partitioned structure on the optical film; aligning or overlapping the side edges of main bodies of adjacent liquid crystal panels, and putting them over the partitioned structure; and providing a protection layer having a micro-structure over a main body of a liquid crystal panel, thus forming an LCD display. A seamless display, comprises: a backlight module, that includes a plurality of light emitting sources; an optical film; a partitioned structure; a plurality of LCD panel main bodies; a protection layer having a micro-structure; and a locking portion. The main bodies of a plurality of liquid crystal panels are put together through aligning or overlapping their respective side edges, and then are covered over the partitioned structure.