Abstract:
A liquid crystal display has a frame including a base and a reinforced portion extending from the base, the reinforced portion defining a partial edge of the frame. The liquid crystal display further includes an optical sheet on the base, the optical sheet including a backlight unit, a flexible printed circuit on the optical sheet, and a liquid crystal display panel comprising a large scale integrated circuit, the liquid crystal display panel substantially covering the optical sheet. A window is attached to and substantially covers the frame at least one support extends from the base for supporting the window and/or the backlight unit.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to and the benefit of Korean Patent Application No. 10-2007-0047827, filed on May 16, 2007, the entire content of which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present relates to a liquid crystal display and a manufacturing method thereof, more particularly to a support structure for the liquid crystal display. 
     2. Description of the Related Art 
     Referring to  FIG. 1 , a conventional liquid crystal display typically includes a generally rectangular frame  20  supporting a liquid crystal display (LCD) panel  10 . As illustrated in  FIG. 1 , a reinforced frame portion  21  is on three sides of the frame  20 , and an unreinforced frame portion  22 , thinner than the reinforced frame, extends along one side of the frame  20  to accommodate a flexible printed circuit  30  coupled to the LCD panel  10 , the flexible printed circuit adapted to be coupled to an external printed circuit board (PCB). 
     In a conventional LCD, a window  11  is located above a surface of the frame  20  to which the flexible printed circuit  30  is attached. Since the frame  20  has an unreinforced frame portion  22 , external impact or applying force to the window may result in a lower substrate  12  of the LCD panel  10  or a large scale integrated circuit (LSI)  13  on the lower substrate  12  being damaged. 
     SUMMARY 
     Aspects of the present invention provide a liquid crystal display and a manufacturing method thereof for preventing a panel or an LSI from being damaged by an external impact or pressure of a window due to at least one support supporting a backlight unit (BLU) and/or the window. 
     In one embodiment, a liquid crystal display has a frame including a base and a reinforced portion extending from the base, the reinforced portion defining a partial edge of the frame. The liquid crystal display further includes an optical sheet on the base, the optical sheet including a backlight unit, a flexible printed circuit on the optical sheet, and a liquid crystal display panel comprising a large scale integrated circuit, the liquid crystal display panel substantially covering the optical sheet. A window is attached to and substantially covers the frame at least one support extends from the base for supporting the window and/or the backlight unit. 
     In one embodiment, the at least one support is a pillar having any one cross-sectional shape selected from a circle, a triangle, and a rectangle. Further, the at least one support protrudes into a space between the large scale integrated circuit and the window to protect the large scale integrated circuit and/or the liquid crystal display panel from an external impact or pressure. The flexible printed circuit may include at least one through hole through which the at least one support protrudes. Further, a height of the at least one support may be about equal to a thickness of the reinforced portion. 
     Also provided is a method for manufacturing a liquid crystal display including providing a frame having at least one support extending from the frame in a thickness direction, forming a base layer of a panel by placing an optical sheet on the frame, placing a flexible printed circuit on one side of the optical sheet, placing a liquid crystal display panel on the optical sheet, the liquid crystal display panel including a large scale integrated circuit, and placing a window or a backlight unit onto the frame such that the at least one support provides support to the window or backlight unit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  illustrates a general liquid crystal display. 
         FIG. 2A  is an exploded perspective view illustrating a liquid crystal display according an exemplary embodiment of the present invention. 
         FIG. 2B  is a cross-sectional view of  FIG. 2A  taken along the line  1 - 1 ″. 
         FIG. 3   a  to  3   d  are perspective views illustrating a mold structure of a liquid crystal display according an exemplary embodiment of the present invention. 
         FIG. 4  is a front view illustrating a mold structure of a liquid crystal display according an exemplary embodiment of the present invention. 
         FIG. 5   a  and  FIG. 5   b  are views illustrating a state which a window is formed on a panel and a mold of a liquid crystal display using a mold structure of a liquid crystal display according an exemplary embodiment of the present invention. 
         FIG. 6   a  to  FIG. 6   c  are perspective views illustrating a mold structure of a liquid crystal display according another exemplary embodiment of the present invention. 
         FIG. 7   a  to  FIG. 7   c  are perspective views illustrating a mold structure of a liquid crystal display according another exemplary embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     In the following detailed description, only certain exemplary embodiments of the present invention are shown and described, by way of illustration. As those skilled in the art would recognize, the invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Like reference numerals designate like elements throughout the specification. 
     With reference now to  FIG. 2 , the liquid crystal display  1100  according to an embodiment of the present invention includes a frame  1110 , a base layer  1120  of a panel, a flexible printed circuit  1130 , a LCD panel  1140  and a window  1150 . 
     The frame  1110  is a basic frame for a liquid crystal display, and as illustrated in  FIG. 2 , the frame  1110  includes a reinforced portion  1111 , a base  1112 , and a support  1113 . 
     The reinforced portion  1111  has a constant thickness and partially extends along an edge of the frame  1110 . In one embodiment, the reinforced portion  1111  supports the window  1150  and the LCD panel  1140 . Due to the constant thickness of the reinforced portion  1111 , impact transferred to the frame  1110  is minimized by being dispersed throughout the window  1150 . 
     The base  1112  extends between a portion of the frame  1110  absent the reinforced portion  1111 , the base adapted to accommodate the flexible printed circuit  1130 . The flexible printed circuit  1130  is required for coupling the LCD panel  1140  to a BLU and for coupling the LCD panel  1140  to an external printed circuit board (PCB). 
     The support  1113  is located in the base  1112 , protrudes from the base to about a height of the reinforced portion  1111 . Referring to  FIG. 2 , the support  1113  includes two protrusions in the base  1112 , and in one embodiment the protrusions are cylindrical. 
     The support  1113  is between the window  1150  and the base  1112  of the frame  1110  and supports the window  1150 . A lower substrate  1142  and an LSI  1143  of the LCD panel  1140  are located between the window  1150  and the base  1112 . 
     In a conventional liquid crystal display device, if an external impact or pressure is applied to a top surface of the base  1112 , the LCD panel  1140  or LSI  1143  could be easily cracked. 
     However, since a liquid crystal display  1100  according an exemplary embodiment of the present invention includes the support  1113 , the likelihood of an external impact causing a crack in the LCD panel  1140  or in the LSI  1143  can be reduced or prevented. To be more specific, the support  1113  protrudes from the base  1112  such that its height is about equal to a height of the reinforced portion  1111 . Therefore, when the window  1150  is on the frame  1110 , the window  1150  contacts the reinforced portion  1111  and the support  1113  of the frame  1110 . Consequently, when an external impact or pressure is applied to the base  1112  via the window  1150 , the reinforced portion  1111  and the support  1113  disperse the impact throughout the frame  1110  with the support being able to withstand the external impact. Consequently, the lower substrate  1142  and the LSI  1143  of the LCD panel  1140  between the window  1150  and the base  1112  may be protected from external impact or pressure. Therefore, a LCD panel or a LSI may be prevented from being damaged. 
     A liquid crystal display  1100  according embodiments of the present invention may prevent a LCD panel or an LSI from being damaged by an external impact or pressure due to the support  1113  in the base  1112  of the frame  1110 . The base layer  1120  of a panel is located within the frame  1110 . As illustrated in  FIG. 2 , the base layer  1120  of a panel may include a reflection plate  1121 , a light guiding plate  1122 , an optical sheet  1123 , and a BLU  1124 . 
     The reflection plate  1121  contacts the base  1112  and reflects light from the BLU  1124  and enables the reflected light to be incident on the LCD panel  1140 . The reflection plate  1121  is primarily composed of a polyester (PET) material, and reflects light to reduce the loss of light incident on the light guiding plate  1122 . 
     The light guide plate  1122  is on top of the reflection plate  1121  and is composed primarily of acryl poly(methyl methacrylate) (PMMA). A pattern constituted by guiding the incident light source uniformly distributes the light. The light guide plate  1122  may be manufactured by injection molding or by casting. 
     The optical sheet  1123  is on top of the light guiding plate  1122 , and may include two diffusion sheets and two prism sheets between the two diffusion sheets. The diffusion sheet is primarily manufactured by using acrylic based resin on the substrate of polyester PET and being formed into a spherical shape for uniformly distributing the light emitted from the light guide plate  1122  and simultaneously condensing the light. The diffusion sheet primarily serves to protect the prism sheet, and the diffusion sheet may also be referred to as a protective film. The prism sheet is primarily composed of an acrylic based resin on the substrate of polyester PET and condenses light by being formed into a regular prism shape. 
     The BLU  1124  is a light source that receives a high voltage from an inverter and then generates a visible ray. A Cold Cathode Fluorescent Lamp (CCFL) is typically used as the BLU. 
     As illustrated in  FIG. 2 , the flexible printed circuit  1130  is on a top surface of the base layer  1120  of a panel, and more specifically on a front surface of the optical sheet  1123  in the base layer  1120 . The flexible printed circuit  1130  electrically couples the BLU  1124  to the LSI  1143 , and the LSI  1143  to an external PCB. 
     Through holes  1131  in the flexible printed circuit are located corresponding to the support  1113  through which the support  1113  protrudes to allow the flexible printed circuit  1130  to be easily coupled to the support and fixed thereto. 
     Generally, the LCD panel  1140  includes an upper substrate  1141  on which a color filter and a black matrix are formed; a lower substrate  1142  on which a thin-film transistor is formed; and a liquid crystal injected between the upper substrate  1141  and the lower substrate  1142 . The LSI  1143  may be located on a top surface of the upper substrate  1141 . 
     The LSI  1143  drives the BLU  1124  and the LCD panel  1140 , and is electrically coupled to the BLU  1124  and to the external PCB via the flexible printed circuit  1130 . Since the LSI  1143  receives an electrical signal from the external PCB, the BLU  1124  emits light for displaying an image on the LCD panel  1140 . 
     The LSI  1143  may be located in the space between the base  1112  and the window  1150 , and more specifically, on the top surface of the lower substrate  1142 . 
     The window  1150  is located on a top surface of the LCD panel  1140 . The window  1150  protects internal circuitry of a product using a LCD panel according to the present invention. As illustrated above, the window  1150  is supported by the reinforced portion  1111  of the frame  1110  and the support  1113 . 
     In many conventional LCD devices, there is no structure for supporting a space between the base  1112  and the window  1150 . Therefore, when an external impact or pressure is applied to a portion of the window over the space, the LCD panel  1140  or the LSI  1143  could be easily damaged. 
     However, as illustrated above, in the liquid crystal display  1100  according to an exemplary embodiment of the present invention, the support  1113  is located between the base  1112  and the window  1150  to prevent the LCD panel  1140  and the LSI  1143  from being damaged by external impact or pressure. 
     Below, the structure of various frames  1110 ,  1210 ,  1310 ,  1410  for liquid crystal displays according to embodiments of the present invention will be explained with reference to  FIGS. 3   a - 3   d.    
     With reference to  FIG. 3   a , the frame  1110  of the liquid crystal display  1100  according to an exemplary embodiment of the present invention includes the reinforced portion  1111 , the base  1112 , and two supports  1113  in a cylindrical pillar shape, as described above with reference to  FIG. 2 . Although the supports  1113  are shown spaced by a specific interval, one of ordinary skill in the art will appreciate that a space between the supports  1113  may vary without departing from the spirit and scope of the present invention. 
     Referring to  FIG. 3   b , the structure of the frame  1210  according to another embodiment of the present invention is illustrated, the frame  1210  being substantially similar to the frame  1110  as described above. However, as illustrated in  FIG. 3   b , only a single support  1213  is provided in a cylindrical pillar shape. Although the support  1213  is in the middle of the base, the position is not limited thereto. 
     With reference now to  FIG. 3   c , the frame  1310  is substantially similar to the frame  1110 , as described above. However, three supports  1313  are provided, evenly spaced along the base  1112 . However, the specific position of the supports is not limited thereto. 
     Similarly, with reference to  FIG. 3   d , the frame  1410  is substantially similar to the frame  1110 , as described above. Three supports  1413  are provided, with at least one of the supports  1413  linearly offset from the other two. As such, since the supports  1413  are not in a straight line, the support for the window  1150  may be increased. As will be appreciated, the specific positioning of the supports  1413  is not limited to that shown in  FIG. 3   d.    
     With reference now to  FIG. 4 , the window  1150  is shown supported by the reinforced portion  1111  and the supports  1113 . As can be seen, a height of the supports  1113  is relatively equal to a thickness of the reinforced portion  1111 . 
     With reference now to  FIG. 5   a , the support  1113  includes two cylinders in the frame  1110  having the flexible printed circuit attached thereto. Further, the supports  1113  protrude through the through holes  1131  in the flexible printed circuit  1130  to allow the flexible printed circuit  1130  to electrically couple the BLU  1124  and the LSI  1143  via the through hole  1131 . 
     Referring to  FIG. 5   b , the window  1150  is formed on the upper side of the LCD panel  1140 . The window  1150  is supported by the frame  1110 , and more specifically, it is supported by the reinforced portion  1111  and the support  1113  of the frame  1110 . 
     Referring now to  FIGS. 6   a - 6   c , various frames  2110 ,  2210 ,  2310  according to other embodiments of the present invention are provided. Similarly to the previously described frames, the frame  2110  includes the reinforced portion  1111 , the base  1112 , and a support formed on an upper surface of the base  1112 . 
     Referring to  FIG. 6   a , a support  2113  includes two pillars having a rectangular cross-section spaced along the upper surface of the base  1112 . A height of the support  2113  is about equal to the height of the reinforced portion  1111 . As will be appreciated, the specific configuration of the support  2113  is not limited to that shown and described. 
     As shown in  FIG. 6   b , a support  2213  is provided including a single pillar having a rectangular cross-section on the upper surface of the base  1112  of frame  2210 . Further, a support  2313  including three pillars having a rectangular cross-section is provided on the upper surface of the base  1112  of frame  2310 . 
     Similarly to the above described frames,  FIGS. 7   a ,  7   b , and  7   c  show additional embodiments of frames  3110 ,  3210 ,  3310  having two supports  3113 , one support  3123 , and three supports  3133 , respectively, each support  3133 ,  3123 , and  3133  having a triangular cross-section. 
     As will be appreciated by one of ordinary skill in the art, the particular shape and number of each support may vary, and the supports are not limited to the number and shapes described herein. 
     Below, a method for manufacturing the liquid crystal display  1100  according to an embodiment of the present invention will be explained. Referring to  FIG. 2 , a method for manufacturing a liquid crystal display  1100  includes steps of preparing a frame; providing a base layer of a panel; providing a flexible printed circuit; and providing an LCD panel. 
     The step of preparing a frame includes providing a frame  1110  that has the reinforced portion  1111 , the base  1112  and the support  1113 . Unlike a conventional frame, the frame  1110  includes the support  1113  on the upper surface of the base  1112 . 
     The step of providing a base layer of a panel includes forming the base layer  1120  of a panel including a reflection plate  1121 , a light guiding plate  1122 , an optical sheet  1123 , a BLU  1124 , and the like on the upper surface of the frame  1110 . The BLU  1124  may also be formed on the exterior surface of the frame and on the upper surface of the frame according to the desired configuration, and the present invention does not limit the position of the BLU  1124 . 
     The step of providing a flexible printed circuit includes forming the flexible printed circuit  1130  on the optical sheet  1123  of the base layer  1120  of a panel. As illustrated above, through holes  1131  located corresponding to the support  1113  are provided in the flexible printed circuit  1130  through which the support  1113  protrudes. 
     The step of providing an LCD panel includes forming the LCD panel  1140  on the top surface of the base layer  1120  of a panel. The LCD panel  1140  includes an upper substrate  1141  on which a color filter and a black matrix are formed; a lower substrate  1142  on which a thin-film transistor is formed; and a liquid crystal injected between the upper substrate  1141  and the lower substrate  1142 . As illustrated above, the LSI  1143  is located on a surface of the lower substrate  1142 . 
     As illustrated above, a liquid crystal display and a manufacturing method thereof according to embodiments of the present invention may prevent a panel and/or an LSI from being damaged by external impact and/or pressure on the window  1150  due to at least one support supporting a BLU and the window. 
     While the present invention has been described in connection with certain exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof. For example, it will be appreciated that the supports may be one of a variety of different shapes, including hexagonal or octagonal, and that there may be more than three supports.