Patent Publication Number: US-2017371185-A1

Title: Structure for curved display device and method of manufacturing frame for curved display device using the same

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional application of U.S. patent application Ser. No. 14/918,343 filed on Oct. 20, 2015, which claims priority to Korean Patent Application No. 10-2015-0026804, filed on Feb. 25, 2015 in the Korean Intellectual Property Office (KIPO), and all the benefits accruing therefrom under 35 U.S.C. §119, the contents of the prior applications being herein incorporated by reference. 
    
    
     BACKGROUND 
     (a) Field 
     The present invention relates to a structure for a curved display device and a method of manufacturing a frame for a curved display device using the same. 
     (b) Description of the Related Art 
     In accordance with the demand of consumers for larger screens, the size of image display devices such as televisions (TVs) has gradually increased with time. However, as screen sizes grow, the distance from the eyes of the viewer to both end portions of the image display device becomes significantly larger than a distance from the eyes of the viewer to a central portion of the image display device. This difference reduces the viewer&#39;s sense of immersion. 
     In order to solve this problem, a method of improving immersion by forming the image display device in a curved shape has been used. In order to manufacture the curved image display device, a method of compressing and manufacturing a frame, which is a body, using press equipment is generally used. A length at which two molds closely adhering to the frame at upper and lower sides, respectively, in the press equipment are vertically maximally spaced apart from each other is called a stroke length. 
     However, in the case of image display devices having large screens, a very large space is required in a press process due to the size of the frame and the amount by which it must be bent. This requires press equipment with larger and larger stroke lengths. However, this results in increased manufacturing cost. In addition, the resulting increased movement length of the mold in the press equipment also results in increased process time. 
     The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. 
     SUMMARY 
     Embodiments of the present invention provide a structure for a curved display device and a method of manufacturing a frame for a curved display device using the same. Embodiments of the invention provide the advantages of manufacturing a component for a large-screen curved display device without need for separate press equipment. 
     An exemplary embodiment of the present invention provides a structure for a curved display device, that includes: a plurality of unit body parts each comprising a sheet bent into an arcuate shape; and at least one bent part through which adjacent ones of the unit body parts are connected. 
     The unit body parts may include: base parts connected to each other through respective ones of the at least one bent part; and at least one extension part extending from the corresponding base part. 
     The unit body parts may each have the same radius of curvature. 
     The unit body parts may have different radii of curvature. 
     The at least one bent part may comprise more than one bent part, and the bent parts may be formed at predetermined intervals. 
     Another exemplary embodiment of the present invention provides a method of manufacturing a frame for a curved display device, the method including: receiving a structure for a curved display device, the structure comprising a plurality of unit body parts, and at least one bent part through which adjacent ones of the unit body parts are connected; bending the unit body parts so that each unit body part has an arcuate shape; and bonding two adjacent unit body parts to each other. 
     In the structure for a curved display device according to an exemplary embodiment of the present invention, the unit body parts are connected to each other by the bent part. Therefore, when there is a space corresponding to a height occupied by one unit body part, the structure for a curved display device may be easily manufactured using the press equipment. 
     More specifically, since the structure for a curved display device may be manufactured without increasing a stroke length of the press equipment, a press equipment having a significantly large stroke length does not need to be separately prepared. Therefore, manufacturing cost may be decreased. Also, in the case of manufacturing the structure for a curved display device according to an exemplary embodiment of the present invention, the number of unit body parts is increased to decrease a height occupied by the unit body parts, such that a movement length of a mold in the press equipment may be further decreased as compared with the related art. Therefore, a tack time is decreased, thereby making it possible to significantly increase productivity. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view illustrating a structure for a curved display device according to an exemplary embodiment of the present invention. 
         FIG. 2A  is a front view and a plan view illustrating the structure of  FIG. 1 . 
         FIG. 2B  is a front view and a plan view illustrating a structure for a curved display device according to another exemplary embodiment of the present invention. 
         FIG. 2C  is a front view and a plan view illustrating a structure for a curved display device according to yet another exemplary embodiment of the present invention. 
         FIG. 3  is a view illustrating a process of manufacturing a structure for a curved display device according to an exemplary embodiment of the present invention using a press. 
         FIG. 4  is a flow chart illustrating a method of manufacturing a frame for a curved display device according to an exemplary embodiment of the present invention. 
         FIGS. 5A to 5C  are views illustrating various methods of bonding extension parts to each other. 
         FIG. 5A  is a view illustrating a state of bonding the extension parts to each other by a method by welding. 
         FIG. 5B  is a view illustrating a process of bonding the extension parts to each other. 
         FIG. 5C  is a view illustrating another process of bonding the extension parts to each other. 
         FIG. 6  is a perspective view illustrating a frame along with the curved display device structure of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art to which the present invention pertains may easily practice the present invention. However, the present invention may be implemented in various different forms and is not limited to exemplary embodiments provided herein. 
     Portions unrelated to the description will be omitted in order to obviously describe the present invention, and similar components will be denoted by the same reference numerals throughout the present specification. 
     In addition, in several exemplary embodiments, components having the same configuration will be representatively described using the same reference numerals in an exemplary embodiment, and only components different from those of an exemplary embodiment will be described in the other exemplary embodiments. 
     Throughout the present specification, when any one part is referred to as being “connected to” another part, it means that any one part and another part are “directly connected to” each other or are “indirectly connected to” each other with the other part interposed therebetween. In addition, throughout the present specification, unless explicitly described to the contrary, the word “comprise” and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of stated elements but not the exclusion of any other elements. 
     The various Figures are not necessarily to scale. All numerical values are approximate, and may vary. All examples of specific materials and compositions are to be taken as nonlimiting and exemplary only. Other suitable materials and compositions may be used instead. 
       FIG. 1  is a perspective view illustrating a structure for a curved display device according to an exemplary embodiment of the present invention, and  FIG. 2A  is a front view and a plan view illustrating the structure of  FIG. 1 . 
     Referring to  FIGS. 1 and 2A , the structure  100  for a curved display device according to an exemplary embodiment of the present invention is configured to include a plurality of unit body parts  110  and at least one bent part  120 . 
     The unit body part  110  has an arc shaped cross section and a thin sheet-like shape. In the structure  100  for a curved display device according to an exemplary embodiment of the present invention, multiple unit body parts  110  are connected in parallel with each other. Sizes of the unit body parts  110  may be different from each other. 
     For example, in the case in which the structure  100  for a curved display device according to an exemplary embodiment of the present invention is configured of three unit body parts  110  as illustrated in  FIG. 1 , a size of a central unit body part  110  may be larger than those of unit body parts  110  positioned at both sides thereof. The sizes of any of these unit body parts  110  may vary. For example, although not illustrated in the accompanying drawings, sizes of the respective unit body parts  110  may be the same as each other. 
     The bent parts  120  allow the unit body parts  110  to be connected to each other in a bent state. Although the bent part  120  may be manufactured separately from the unit body part  110  and may be coupled to the unit body part  110 , it may be advantageous in terms of convenience of manufacturing to manufacture the bent part  120  and the unit body part  110  integrally with each other. The bent parts  120  may be bent at a specific angle, which may be any desired angle and which may vary as desired. 
     Meanwhile, a unit body  110  may include, for example, a base part  111  and at least one extension part  112 . 
     The base parts  111  have ends connected to each other via the bent part  120 . The base part  111  may have, for example, a rectangular shape or a square shape. 
     The extension part  112  is located at an end of the base part  111 . The extension parts  112  may be formed at a side perpendicular to a side at which the base parts  111  are connected to each other. That is, in the case in which left and the right sides of the base parts  111  are coupled to each other, the extension parts  112  may be formed at upper sides or lower sides of the base parts  111 . The extension parts  112  may be formed at only the upper sides of the base parts  111 , only the lower side of the base parts  111 , or at both upper and lower sides thereof. 
     The extension part  112  may be made of the same material as that of the base part  111 . A thickness of the extension part  112  may be the same as that of the base part  111 . The extension part  112  may be formed integrally with the base part  111  in a manufacturing process. 
     Meanwhile, the plurality of unit body parts  110  may have the same radius of curvature. Alternatively, the plurality of unit body parts  110  may have different radii of curvature. That is, since the respective radii of curvature of the unit body parts  111  may vary from manufacturer to manufacturer, the radii of curvature of the unit body parts  110  are not limited to any specific values. 
     The number of bent parts  120  may be plural, and the bent parts  120  may be formed at predetermined intervals. 
       FIG. 2B  is a front view and a plan view illustrating a structure for a curved display device according to another exemplary embodiment of the present invention. 
     As illustrated in  FIG. 2B , in the case in which the structure  100  for a curved display device according to an exemplary embodiment of the present invention is configured of two unit body parts  110 , only one bent part  120  is present. 
       FIG. 2C  is a front view and a plan view illustrating a structure for a curved display device according to yet another exemplary embodiment of the present invention. 
     As illustrated in  FIG. 2C , in the case in which the structure  100  for a curved display device according to an exemplary embodiment of the present invention is configured of four unit body parts  110 , the number of bent parts  120  may be three, and the bent parts  120  may be spaced apart from each other by a predetermined distance. Any distance or distances may be employed. 
       FIG. 3  is a view illustrating a process of manufacturing a structure for a curved display device according to an exemplary embodiment of the present invention using press equipment. 
     In the structure  100  for a curved display device according to an exemplary embodiment of the present invention having the above-mentioned structure, the unit body parts  110  are connected to each other in parallel by the bent parts  120 . Therefore, when the press has at least an amount of space corresponding to a height occupied by one unit body part  110 , the structure  100  for a curved display device may be readily manufactured using the press equipment. 
     Thus, since the structure  100  for a curved display device may be manufactured without increasing a stroke length h of the press equipment  10 , custom press equipment having a significantly larger stroke length does not need to be separately prepared. Therefore, a manufacturing cost may be decreased. 
     Rather, in the case of manufacturing the structure  100  for a curved display device according to an exemplary embodiment of the present invention, the number of unit body parts  110  is increased to decrease a height occupied by the unit body parts  110 , such that a movement length h of a mold  11  in the press equipment  10  may be further decreased as compared with the related art. Therefore, a tack time is decreased, or process time is reduced, thereby making it possible to significantly increase productivity. 
     Next, a method of manufacturing a frame for a curved display device using the structure for a curved display device having the above-mentioned structure will be described with reference to the accompanying drawings. 
       FIG. 4  is a flow chart illustrating a method of manufacturing a frame for a curved display device according to an exemplary embodiment of the present invention. 
     Referring to  FIG. 4 , the method (S 500 ) of manufacturing a frame for a curved display device according to an exemplary embodiment of the present invention includes preparing the structure for a curved display device described above (S 510 ), bend structure to form bent parts and to impart arcuate shape to unit body part (S 520 ), and bonding two adjacent extension parts to each other (S 530 ). 
     In (S 510 ), the structure for a curved display device configured of the unit body parts and the bent parts is prepared. The number of unit body parts configuring the structure for a curved display device may be freely changed depending on a design. 
     In (S 520 ), a general method of bending a plate shaped, or sheet-like, object using a separate jig or tool may be used. Such methods are known. Therefore, a detailed description for this will be omitted. 
     In (S 530 ), the two adjacent extension parts are bonded to each other so as not to be separated from each other. 
       FIGS. 5A to 5C  are views illustrating various methods of bonding extension parts to each other. 
       FIG. 5A  is a view illustrating the bonding of extension parts to each other by a method y welding,  FIG. 5B  is a view illustrating the attaching of extension parts to each other by bolt, and  FIG. 5C  is a view illustrating the bonding of extension parts to each other by a fixing pin. As illustrated in  FIGS. 5A to 5C , any methods used to bond parallel metal plates to each other may be used to bond the extension parts  112 . Therefore, a method of bonding the extension parts  112  to each other is not limited to the specific methods shown, and any other method is contemplated as well. 
       FIG. 6  is a perspective view illustrating a frame along with the curved display device structure of  FIG. 1 . 
     As illustrated in  FIG. 6 , the frame  400  may have an arcuate shape. The frame  400  may be used as a main frame in which various components are mounted in a curved television (TV). 
     While this invention has been described in connection with what is presently considered to be practical 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. Therefore, it will be understood by those skilled in the art that various modifications and other equivalent exemplary embodiments may be made from the present invention. Therefore, an actual technical protection scope of the present invention is to be defined by the claims. Furthermore, different features of the various embodiments, disclosed or otherwise understood, can be mixed and matched in any manner to produce further embodiments within the scope of the invention. 
     DESCRIPTION OF SYMBOLS 
     
         
         
           
               100 ,  200 ,  300 : structure for curved display device 
               400 : frame for curved display device 
               110 : unit body part 
               111 : base part 
               112 : extension part 
               120 : bent part