Segmented Back Frame with Adjustable Bracing for Display Cost Reduction
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Solution Overview
Problem
The high material and mold costs associated with conventional back frames for liquid crystal display devices, which are often made from either expensive aluminum for better heat dissipation or cost-effective galvanized steel with poor heat dissipation, necessitate a solution that balances material selection with cost efficiency.
Innovation Solution
A back frame design comprising primary and secondary assembling pieces with adjustable bracing, where primary pieces with heat sources have enhanced heat transfer capabilities and those without have greater structural strength, using a combination of aluminum and galvanized steel, and an adjustable bracing piece for selective mounting to optimize heat dissipation and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the whole back panel is made of aluminum material, then the heat dissipation performance is improved, but the material cost increases and structural strength deteriorates
Solution Approach 1:
The back frame is divided into different material regions: aluminum alloy pieces are used in areas requiring heat dissipation (near heat sources), while galvanized steel pieces are used in areas requiring structural strength. This local differentiation allows each region to have optimal material properties, achieving both heat dissipation performance and cost reduction.
Solution Approach 2:
The back frame employs a composite structure combining aluminum alloy pieces and galvanized steel pieces. This composite approach leverages the advantages of both materials: aluminum's superior heat dissipation and steel's strength and cost-effectiveness, creating a back frame that balances thermal performance, structural integrity, and material cost.
2Strength
If a unitary back frame is made with metal stamping or plastic injection molding, then the structural integrity is improved, but the material cost and mold cost increase
Solution Approach 1:
The back frame is segmented into multiple independent pieces (aluminum alloy pieces and galvanized steel pieces) that are connected through joining. This segmentation allows for optimized material selection in different regions, reduced material waste, and lower mold costs compared to producing a single large unitary frame.
Solution Approach 2:
Multiple separate pieces (aluminum alloy pieces and galvanized steel pieces) are merged through joining connections to form the complete back frame structure. This merging approach maintains structural integrity while enabling material optimization and cost reduction that would not be possible with a unitary construction method.
3Area of stationary object
If a large-sized back frame is made, then the display size capability is improved, but the stamping equipment size and mold complexity increase
Solution Approach 1:
The large back frame is divided into multiple smaller pieces that can be manufactured using standard-sized stamping equipment and simpler molds. These segmented pieces are then assembled to form the complete large-sized back frame, avoiding the need for oversized equipment and complex large-scale molds.
Solution Approach 2:
The back frame construction transitions from a single-plane unitary structure to a multi-piece assembled structure. This dimensional reorganization allows large frames to be built from smaller standardized components, reducing mold complexity and equipment size requirements while maintaining the overall large footprint needed for big displays.
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 reduces material and mold costs by allowing for the use of different materials based on heat dissipation needs while maintaining structural integrity, and the adjustable bracing simplifies the manufacturing process, making it suitable for various display sizes.
Implementation Method 1
a primary assembling piece that has a heat source arranged thereon, the primary assembling piece that has the heat source arranged thereon having a first heat transfer capability
Data Source
AI summary
The present invention provides a back frame of flat panel display device, which includes primary assembling pieces, secondary assembling pieces, and an adjustable bracing piece. The primary assembling pieces have a number of at least two, and the at least two primary assembling pieces are connected through joining to form a main frame structure of the back frame. The secondary assembling pieces are joined to the primary assembling pieces. According to practical needs of the main frame structure, different materials are used for primary assembling pieces at different locations. The back frame further includes the bracing piece that is mounted to the primary assembling pieces or the secondary assembling pieces. The available mounting points between the bracing piece and the primary assembling pieces or the secondary assembling pieces are of a number of at least two so that the bracing piece is selectively mounted to the back frame at different positions. The present invention also provides a backlight system. The back frame and the backlight system of the present invention have a simple back frame structure, reduce the expenditure of the back frame mold, and also save the material used for back frame so as to lower down the cost of flat panel display device and meet different requirements for mounting.