Segmented Backlight Substrates for LCD Repair and Brightness
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Solution Overview
Problem
As liquid crystal display devices increase in size, the precision in matching openings in a reflective sheet with LED arrangements on support substrates becomes difficult, and replacing individual substrates requires peeling off the entire reflective sheet, leading to increased manufacturing costs and reduced repairability.
Innovation Solution
Divide the region with point light source elements into smaller regions, each with its own support substrate and corresponding backlight unit, and form the reflective sheet into multiple smaller regions that cover the entire area, allowing for adjustable center-to-center distances between LEDs and overlapping sheets to maintain uniform brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single large support substrate is used for large screen liquid crystal display devices, then the backlight can cover the entire screen area, but the manufacturing cost increases and repairability deteriorates
Solution Approach 1:
The backlight is divided into multiple smaller support substrates (first, second, third, and fourth support substrates) that can be manufactured separately and then assembled together. Each substrate contains a portion of the LED array and corresponding reflective sheet, enabling modular manufacturing and replacement while covering the entire large screen area.
2Area of stationary object
If a single large support substrate is used, then the backlight covers the entire screen, but repairability deteriorates as the entire substrate must be replaced for any defect
Solution Approach 1:
The backlight is segmented into multiple independent support substrates that can be replaced individually. If a defect occurs in one substrate, only that specific substrate needs to be replaced rather than the entire backlight assembly, significantly improving repairability while maintaining full screen coverage.
Solution Approach 2:
The modular substrate design allows for selective replacement of defective portions. Healthy substrates can be retained and reused, while only the defective substrate is discarded and replaced, reducing waste and repair costs.
3Area of stationary object
If the reflective sheet is made as one large piece to cover all support substrates, then the entire region is covered, but replacement of individual substrates requires peeling off the entire reflective sheet
Solution Approach 1:
The reflective sheet is divided into multiple smaller reflective sheets, with each reflective sheet corresponding to a specific support substrate. This segmentation allows individual reflective sheets to be removed and reattached when replacing substrates, eliminating the need to peel off the entire reflective sheet and simplifying repair procedures.
4Illumination intensity
If point light source elements are regularly aligned in a plane, then the backlight provides uniform illumination, but matching openings in the reflective sheet with LED positions becomes difficult as device size increases
Solution Approach 1:
The LED array and reflective sheet are both segmented into corresponding modules on each support substrate. This modular approach allows for precise alignment of openings with LED positions on each smaller substrate, avoiding the cumulative alignment errors that would occur with a single large substrate while maintaining uniform illumination across the entire backlight.
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 simplifies assembly and replacement, maintains uniform brightness by adjusting LED intervals, and reduces manufacturing costs by allowing for localized repair of support substrates without affecting overall brightness, ensuring high-quality images.
Implementation Method 1
a reflective sheet 4 where openings 40 are created in positions where LED's are provided is placed on the support substrate 3. This works to direct light emitted from the LED's in the direction towards the liquid crystal panel provided in front of the backlight.
Data Source
AI summary
An object of the present invention is to provide a backlight for a liquid crystal display device which is easy to repair and prevents the brightness from lowering on the screen, and thus can provide high-quality images, where the region where point light source elements are aligned is divided into a number of smaller regions, and backlight units are provided so as to correspond to the respective smaller regions, as well as a liquid crystal display device using the same. The present invention provides a backlight for a liquid crystal display device where a number of point light source elements 2 are aligned in a plane, having: a number of backlight units, each of which is formed of a support substrate 31, 32 for supporting point light source elements 2 and point light source elements 2 arranged on the support substrate, the region in which the point light source elements are aligned being divided into a number of smaller regions, each of which having a backlight unit; and a reflective sheet provided on the support substrates of the backlight units, having openings created at points where the point light source elements are located, characterized in that the reflective sheet is formed of a number of sheets 41, 42 and covers the entire region.