Split Reflector Plate Alignment for Mini LED Backlight Stability
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Solution Overview
Problem
The traditional reflector plate design for Mini LED backlights is inadequate due to the large number of holes required, leading to alignment challenges and stability issues, particularly in corner positions, which affect the visual stability and manufacturability of Mini LED backlight systems.
Innovation Solution
A split reflector plate design with a main reflector plate and side reflector plates, featuring precise and coarse positioning mechanisms, alignment marks, and a full laminated reflector plate with a glue layer and scattered particle layer to improve alignment and stability, ensuring accurate positioning and uniform light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a traditional reflector plate is used with many holes for Mini LEDs, then the number of Mini LEDs can be increased, but the alignment precision and visual stability deteriorate due to splicing deviation in corner positions
Solution Approach 1:
The reflector plate is divided into multiple separate reflector pieces that are spliced together. Each reflector piece has positioning structures (positioning grooves and positioning protrusions) that enable precise alignment during assembly, thereby maintaining high alignment precision even when the overall reflector plate is segmented to accommodate numerous Mini LEDs
Solution Approach 2:
Positioning grooves and positioning protrusions are pre-formed on the reflector pieces before assembly. These pre-formed positioning structures ensure accurate alignment during the splicing process, preventing deviation in corner positions and maintaining manufacturing precision throughout the assembly process
2Manufacturing precision
If the reflector plate is divided into multiple spliced pieces, then the alignment can be improved through positioning structures, but the device complexity increases
Solution Approach 1:
The reflector plate is segmented into multiple pieces with standardized positioning structures. While this increases the number of components, each piece remains relatively simple in design with standardized grooves and protrusions, making the overall system manageable despite the segmentation
Solution Approach 2:
Multiple reflector pieces are spliced together to form a complete reflector plate assembly. The positioning structures (grooves and protrusions) on adjacent pieces are designed to mate together, merging the separate pieces into a unified structure that achieves both precision and structural integrity
3Ease of manufacture
If splicing positions are located at corner positions, then the reflector plate can be assembled, but shadow problems occur due to splicing deviation
Solution Approach 1:
The positioning structures are designed with asymmetric features where positioning grooves and positioning protrusions are positioned offset from corner positions. This asymmetric positioning ensures that splicing joints do not occur at corners, eliminating the shadow problem while maintaining assembly feasibility through the standardized positioning mechanisms
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
The solution enhances the stability and alignment of the reflector plates, preventing shadow issues and improving the visual and manufacturing stability of Mini LED backlight systems by ensuring accurate and uniform light distribution.
Implementation Method 1
a scattered particle layer arranged on a side of the base material facing away from the glue layer and configured to increase the emergent direction of the reflected light
Implementation Method 2
a glue layer arranged on one side of the base material facing the light board
Data Source
AI summary
Disclosed is a display apparatus. The display apparatus includes: a display panel and a backlight module; where the backlight module includes: a back plane including a plane portion and an inclined portion surrounding the plane portion, where the inclined portion inclines toward a light emitting side of the backlight module, and the inclined portion and the plane portion are arranged at a configured angle; a light board, arranged on the plane portion of the back plane; a split reflector plate, including a main reflector plate and side reflector plates; where the main reflector plate is arranged on a side of the light board facing away from the back plane, the side reflector plates are arranged on a side of the inclined portion of the back plane facing the light board, and splicing positions of the plurality of side reflector plates do not overlap with corner positions of the inclined portion.