Abstract:
A panel display and a method for manufacturing the same are provided. The panel display includes a frame, an elastic pad, and a display panel. The frame has a supporting tray and a side wall which perpendicularly extends from the end of the supporting tray. A groove is formed on the supporting tray adjacent to the foot of the side wall. One end of the elastic pad is located within the groove while the other end leans on the side wall before the display panel is configured with the frame. When entering the display panel into the frame, the edge of the display panel compels the elastic pad to bend and form a bottom portion and a side portion. The bottom portion is accommodated in the groove while the side portion is compressed by the edge of the display panel and lies on the side wall.

Description:
This application claims priority based on a Taiwanese Patent Application No. 098122387 filed on Jul. 2, 2009. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a display device and a method for manufacturing the same. In particularity, the present invention relates to a display device capable of effectively positioning a display panel relative to a frame and a method for manufacturing the same. 
     2. Description of the Prior Art 
     Since display panel devices have advantages such as thinness, light weight, and portability, the demand for display panel devices increases rapidly. As the technologies advance, higher requirements for design and assembly quality of the display panel device are made. In order to improve the life-span and the yield of the product, the design of the display panel device requires continuous improvements. 
       FIG. 1  illustrates a schematic view of a conventional panel display device. The conventional panel display device includes a front frame  10 , a liquid crystal display (LCD) panel  20 , an outer frame  30 , and a backlight module  50 . The outer frame  30  includes a side wall  31  and a support portion  33 , wherein the support portion  33  extends from the side wall  31  toward the center of the outer frame  30 . The LCD panel  20  is disposed on the outer frame  30  and supported by the support portion  33  while the side wall  31  surrounds around the side of the LCD panel  20 . The backlight module  50  is disposed under the outer frame  30  and the LCD panel  20  and emits lights toward the rear side of the LCD panel  20 . The front frame  10  covers the edge of the LCD panel  20  from the display side of the LCD  20  and the outer side of the outer frame  30  as well. 
     In the conventional design, the outer frame  30  is generally formed of thermosetting plastic materials to provide better support. In addiction, in order to avoid the assembly problem caused by the production tolerance, a gap usually exits between the side wall  31  of the outer frame  30  and the LCD panel  20 . Since the friction generated between the outer frame  30  and the LCD panel  20  is not sufficient, the LCD penal  20  may slide on the outer frame  30  and collide with the outer frame  30  to cause damage. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a display device capable of effectively positioning the display panel with respect to the frame. 
     It is another object of the present invention to provide a display device which reduces the possibility of damaging the display panel. 
     It is yet another object of the present invention to provide a method for manufacturing a display device, which prevents the display panel from being damaged. 
     The display device includes a frame, an elastic pad, and a display panel. The display panel is disposed on the frame and supported by the frame. The elastic pad is sandwiched between the display panel and the frame and configured to position the display panel with respect to the frame. The frame has a supporting tray and a side wall which is connected to the supporting tray and upwardly extends from the end of the supporting tray. The supporting tray and the side wall together form an open accommodating space. A groove is formed on the supporting tray adjacent to the foot of the side wall. 
     The elastic pad has an elastic modulus greater than that of the frame, so that the elastic pad is susceptible to deformation under force. Before the display panel is disposed on the frame and the elastic pad, one end of the elastic pad is located within the groove while the other end leans on the side wall. When the display panel is placed on the frame, the edge of the display panel presses the middle portion of the elastic pad and compels the elastic pad to bend and form a bottom portion and a side portion. The bottom portion is accommodated in the groove while the side portion is compressed by the edge of the display panel and is attached to the inner surface of the side wall. Since a normal force is generated when the display panel presses the side portion, a frictional force is generated between the display panel and the side portion. Therefore, the display panel is not susceptible to move relative to the frame and the positioning effect is achieved. 
     The method of manufacturing a display device includes the following steps: forming a frame in a manner that the frame has a supporting tray and a side wall, and the supporting tray and the side wall together enclose an accommodating space; forming a groove in the supporting tray adjacent to the side wall; disposing an elastic pad in a manner that the elastic pad leans on the side wall and one end of the elastic pad is connected to a bottom of the groove; and disposing a display panel into the accommodating space in a manner that a side edge of the display panel presses the elastic pad so that the elastic pad is bent to form a bottom portion and a side portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a schematic cross-sectional view of a conventional panel display device; 
         FIG. 2  illustrates an exploded view of a display device of the present invention; 
         FIG. 3  illustrates a cross-sectional view of the display device before assembly; 
         FIG. 4  illustrates a cross-sectional view of  FIG. 3  after assembly; 
         FIG. 5  illustrates a cross-sectional view of the display device using a thinner elastic pad; 
         FIG. 6A  illustrates a schematic view of another embodiment of the elastic pad; 
         FIG. 6B  illustrates a schematic view of another embodiment of the elastic pad; 
         FIG. 7A  illustrates a schematic view of an embodiment of a positioning protrusion; 
         FIG. 7B  illustrates a schematic view of  FIG. 7A  after assembly; 
         FIG. 8A  illustrates a schematic view of an embodiment of a recess disposed on the side wall; 
         FIG. 8B  illustrates a schematic view of an embodiment of a lead angle disposed in the side wall; 
         FIG. 9A  illustrates a schematic view of an embodiment of the distribution of the elastic pad; 
         FIG. 9B  illustrates a schematic view of another embodiment of the distribution of the elastic pad; and 
         FIG. 10  illustrates a flow chart of a method for manufacturing a display device. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention provides a display device and a method for manufacturing the same. In a preferred embodiment, the display device of the present invention is a LCD display device including home television, LCD monitor for desktop computer or laptop computer, LCD screen for mobile phone, digital camera, etc. 
     As  FIG. 2  shows, the display device includes a frame  100 , an elastic pad  300 , and a display panel  500 . The display panel  500  is disposed on the frame  100  and supported by the frame  100 . The elastic pad  300  is sandwiched between the display panel  500  and the frame  100  to position a relative position between the display panel  500  and the frame  100 . In the embodiment, the display device further includes a front frame  200  and a backlight module  400 . As  FIG. 2  shows, the front frame  200  covers on the top and the side of the display panel  500  and the frame  100  and exposes a display surface  530  of the display panel  500 . The backlight module  400  is preferably also covered by the frame  100 , but not limited thereto. The backlight module  400  is disposed under the display panel  500  and emits lights toward a bottom surface  510  of the display panel  500 , such that the display panel  500  can display images on the display surface  530  which is opposite to the bottom surface  510 . In other embodiments, however, the display device may not be disposed with the backlight module  400  but adopts the front incident light method. In this case, the display panel  500  is preferably implemented with a display panel eliminating the backlight module  400 , such as a reflective liquid crystal panel or an electrophoretic display panel, etc. In addition to liquid crystal panel and electrophoretic display panel, the display panel  500  may be an organic light-emitting diode panel or other suitable panels. 
     As  FIG. 2  and  FIG. 3  show, the frame  100  has a supporting tray  110  and a side wall  130 . The side wall  130  is connected to the edge of the supporting tray  110  and extends upwardly, i.e., extends toward the direction of the front frame  200 . The portion of the side wall  130  which extends upwardly may cover the side face of the display panel  500 . As  FIG. 3  shows, the supporting tray  110  and the side wall  130  together enclose an open accommodating space. The supporting tray  110  and the side wall  130  are disposed on the bottom and the side of the accommodating space, respectively. In the embodiment, the side wall  130  may also extend downwardly from the edge of the supporting tray  110  to cover the side face of the backlight module  400 . As  FIG. 2  and  FIG. 3  show, a groove  150  is formed in the supporting tray  110  adjacent to the bottom end of the side wall  130 . In the embodiment, the side wall  130  serves as an inner side wall of the groove  150  while the groove  150  extends along the side wall  130  to be a rectangular shape, but not limited thereto. 
     The elastic pad  300  is preferably a rectangular pad which is resilient, and its length is greater than the cross-sectional width of the groove  150 , i.e., a distance from the bottom end of the side wall  130  to the other end of the groove  150 . The elastic pad  300  has an elastic modulus greater than that of the frame  100 . Thus, the elastic pad  300  is susceptible to deformation under force, i.e. is more easily deformed than the frame  100 . As  FIGS. 2 and 3  show, before the display panel  500  is placed on the frame  100  and the elastic pad  300 , the thickness of the elastic pad  300  is preferably greater than the depth of the groove  150 . However, when the display panel  500  is placed on the frame  100 , as shown in  FIG. 4 , the thickness of the elastic pad  300  is preferably compressed to be lightly higher than or similar to the depth of the groove  150 . Furthermore, the elastic pad  300  is preferably made of rubber. In other embodiments, however, the elastic pad  300  may be made of foams, plastics, or non-plastics. 
     Before the display panel  500  is placed on the frame  100  and the elastic pad  300 , one end of the elastic pad  300  is connected to the groove  150 , and the other end leans on the side wall  130 . The elastic pad  300  is preferably a flat elastic pad. However, when the display panel  500  is placed on the frame  100 , as  FIG. 4  shows, the side edge  550  of the display panel  500  presses the middle portion of the elastic pad  300  downwardly, such that the elastic pad  300  is bent to form a bottom portion  310  and a side portion  330 . The bottom portion  310  is accommodated in the groove  150 , and the thickness of the bottom portion  310  is preferably compressed to be similar to the depth of the groove  150 . In the meantime, the bottom portion  310  and the supporting tray  110  of the frame  110  together support the bottom surface  510  of the display panel  500 . In other embodiments, however, the thickness of the bottom portion  310  may be designed to be the same as the depth of the groove  150  when it is not under force and in contact with the bottom surface  510  of the display panel  500 . In the embodiment, the friction coefficient of the bottom portion  310  is preferably greater than that of the supporting tray  110 , such that a greater static friction between the display panel  500  and the bottom portion  310  can be obtained. Thus, the display panel  500  is not susceptible to move and the positioning effect can be achieved. In addition, a normal force is generated when the display panel  500  presses the bottom portion  310 . The normal force also enhances the friction force between the display panel  500  and the bottom portion  310 . 
     As  FIG. 4  shows, the side portion  330  pressed by the side edge  550  of the display panel  500  is in contact with an inner surface of the side wall  130 . Since the side edge  550  of the display panel  500  corresponds to the side wall  130 , the side portion  330  is sandwiched between the side edge  550  of the display panel  500  and the side wall  130 . A normal force is generated as the display panel  500  presses the side portion  330 , such that a frictional force is generated between the display panel  500  and the side portion  330 , and the display panel  500  is accordingly not susceptible to move and the positioning effect can be further enhanced. In the embodiment shown in  FIG. 4 , the bottom surface  510  of the display panel  500  is in contact with the bottom portion  310  of the elastic pad  300  and the friction is accordingly generated therebetween. In other embodiments, however, as shown in  FIG. 5 , the design of a thinner elastic pad  300  or a deeper groove  150  may be implemented, such that the bottom surface  510  of the display panel  500  is not in contact with the bottom portion  310 . In such a case, the display panel  500  is positioned by the friction between the side edge  550  of the display panel  500  and the side portion  330  of the elastic pad  300 . 
     In the embodiment shown in  FIG. 6A  and  FIG. 6B , the side portion  330  and the bottom portion  310  of the elastic pad  300  may have different thickness for different positioning requirements. As  FIG. 6A  shows, the thickness of the side portion  330  is greater than that of the bottom portion  310 . In such a case, the effect of the side portion  330  positioning the side edge of the display panel  500  and its positioning force can be increased. In the embodiment shown in  FIG. 6B , the thickness of the bottom portion  310  is greater than that of the side portion  330 . In such a case, the friction between the bottom portion  310  and the bottom surface  510  of the display panel  500  can be increased to enhance the positioning effect. 
     In the embodiment shown in  FIG. 7A  and  FIG. 7B , a positioning protrusion  331  is formed on the side portion  330  of the elastic pad  300 . As  FIG. 7A  shows, the positioning protrusion  331  is disposed on one side of the side portion  330  which faces toward the display panel  500 . When the display panel  500  is assembled with the frame  100 , the side edge  550  of the display panel  500  presses the elastic pad  300 , such that the side portion  330  is attached to the side edge  550 , i.e. the side portion  330  is preferably substantially completely in contact with the side edge  550 . In such a case, the positioning protrusion  331  contacts and engages with a top end of the side edge  550  of the display panel  500  to prevent the detachment of the display panel  500  from the frame  100 . In the embodiment, the positioning protrusion  331  is preferably formed as a rib and extends along the top end of the side edge  550  of the display panel  500 . In other embodiments, however, the positioning protrusion  331  may be a protrusion or a plurality of protrusion structures. 
     In addition, as  FIG. 8A  shows, a recess  131  is formed in the side wall  130  of the frame  100  corresponding to the elastic pad  300 . Moreover, the location of the recess  131  preferably corresponds to the groove  150 . When the elastic pad  300  is placed on the frame  100 , two sides of the side wall  130  defining the recess  131  can clamp and position the elastic pad  300  therebetween. Furthermore, the depth of the recess  131  can be selected to adjust the tilted angle of the elastic pad  300  when the elastic pad  300  is disposed correspondingly. The recess  131  is preferably recessed from the top end of the side wall  130  toward the direction of the supporting tray  110 , and the portion of the side wall  130  under the recess  131  is left with a height preferably higher than the thickness of the display panel  500 . Thus, when the display panel  500  is assembled with the frame  100 , the side wall  130  may still support the side portion  330  of the elastic pad  300 . In other embodiments, however, the side wall  130  may be formed without the recess  131  and still can achieve the purpose to position the elastic pad  300 . Furthermore, as  FIG. 8B  shows, on the portion of the side wall  130  under the recess  131 , a lead angle  133  is preferably formed at a location where a top end of the portion of the side wall  130  corresponding to the recess  131  meets the inner surface of the side wall  130 . For example, the top corner of the side wall  131  corresponding to the elastic pad  300  can be a rounded corner. Through the design, when the display panel  500  is assembled with the frame  100 , the elastic pad  300  may be moved downward along the lead angle  133  smoothly and bent to be in contact with the side wall  130  and the groove  150 . When the side wall  130  is not disposed with the recess  131 , the lead angle  133  may be applied to the top end of the side wall  130  corresponding to the position of the elastic pad  300 . 
     In the embodiment shown in  FIG. 9A , the elastic pad  300  is preferably distributed uniformly on two ends and the center of each side of the frame  100 . For example, 3 elastic pads are uniformly distributed on one side of the frame  100 , but not limited thereto. In other embodiments, however, in the  FIG. 9B , the elastic pad  300  may be a bar having a length equal to each side of the frame  100  to increase the force of positioning the display panel  500 , but not limited thereto. In addition, by adjusting the width, area, and position of the elastic pad  300 , the force of positioning the display panel  500  can be adjusted and the assembly requirements can be met. 
       FIG. 10  illustrates a flow chart of a method for manufacturing the display device in accordance with an embodiment of the present invention. Step  1010  includes forming a frame  100  in a manner that the frame  100  has a supporting tray  100  and a side wall  130 , and the supporting tray  110  and the side wall  130  together enclose an accommodating space. In an embodiment, the frame  100  is preferably made of thermosetting plastics by injection molding. In other embodiments, however, the frame  100  may be made of different materials and by different processes. 
     Step  1030  includes forming a groove in the supporting tray  110  adjacent to the side wall  130 . In an embodiment, the forming of the groove  150  is to manufacture a mold with a bump corresponding to the groove  150  in advance, and then the groove  150  can be formed adjacent to the side wall  130  simultaneously as the frame  100  is made by injection molding. Moreover, the groove  150  is preferably distributed uniformly on two ends and the center of each side of the frame  100 . In other embodiments, however, the groove  150  can be a bar shaped groove having a length equal to each side of the frame  100 . Furthermore, the side wall  130  can be selectively formed with a recess  131  corresponding to the groove  150 . The top end of the side wall  130  can be selectively formed with a lead angle to facilitate the elastic pad  300  to slide smoothly and to increase the assembly convenience. 
     Step  1050  includes disposing an elastic pad  300  to lean on the side wall  130  so that one end of the elastic pad  300  is connected to a bottom of the groove  150 . The elastic pad  300  preferably leans on the top end of the side wall  130  or can lean on an inner side of the side wall  130 . In the embodiment, the bottom end of the bottom portion  310  of the elastic pad  300  is preferably fixed on the bottom of the groove  150  by adhesive. In other embodiments, however, the end of the bottom portion  310  can be fixed to the groove  150  by latch or other suitable fixing means. Furthermore, the edge of the bottom portion  310  can be just in contact with the edge of the groove  150 . In an embodiment, the thickness of the elastic pad  300  is preferably greater than the depth of the groove  150 . However, in other embodiment, the thickness of the elastic pad  300  can be equal to or smaller than the depth of the groove  150 . The width of the elastic pad  300  is preferably equal to the width of the groove  150 , but not limited thereto. 
     Step  1070  includes disposing a display panel  500  in the accommodating space in a manner that a side edge  550  of the display panel  500  presses the elastic pad  300  so that the elastic pad  300  is bent to form the bottom portion  310  and the side portion  330 . The bottom portion  310  is pressed into the groove  150  while the side portion  330  is compressed by the side edge  550  of the display panel  500  and attached to an inner surface of the side wall  130 . If the thickness of the bottom portion  310  is greater than the depth of the groove  150 , the bottom portion  310  can be compressed to a level same as the depth of groove  150 . A normal force is generated while the display panel  500  presses the side portion  330 , and therefore, a friction is generated between the display panel  500  and the side portion  330 . Accordingly, the display panel  500  is not susceptible to move with respect to the frame  100  and the positioning effect is achieved. In addition, the friction coefficient of the bottom portion  310  is greater than that of the supporting tray  110 . Thus, the static friction between the bottom portion  310  and the bottom surface of the display panel  500  is greater than that between the supporting tray and the bottom surface of the display panel, such that the display panel  500  can not move easily and the positioning effect is achieved. 
     Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims.