A Mini LED Backlight and Its Design Optimization Method

Abstract

This invention proposes a Mini LED backlight and its design optimization method, belonging to the field of novel display optical device technology. The method includes: customizing the selection of diffuser plate substrate to meet the ultra-thin requirements of automotive Mini LED backlights, screening for optical materials with high light transmittance, high weather resistance, and low yellowing; based on different lamp spacing scenarios in vehicles, constructing a customized microstructure array at the position of each LED bead on the diffuser plate, forming a microlens / microprism composite structure precisely matched to the spatial distribution of the LEDs, completing the initial uniform light optical foundation construction; through the composite uniform light technology of customized microstructure array and gradient dot printing, significantly improving the screen brightness uniformity to over 90%, while reducing the module OD value by over 40%, perfectly meeting the ultra-thin design requirements of automotive applications.

Description

Technical Field

[0001] This invention proposes a Mini LED backlight and its design optimization method, belonging to the field of novel display optical device technology. Background Technology

[0002] With the rapid development of automotive display technology, Mini LED backlights have become the mainstream solution due to their advantages such as high brightness and high contrast. However, traditional technical approaches are facing multiple contradictions: to eliminate the light spots generated by high-density LED chips, the diffuser plate needs to adopt a high OD value design, which directly leads to excessive backlight module thickness, seriously conflicting with the trend of ultra-thin automotive devices; increasing the number of LEDs can improve uniformity, but it triggers a chain reaction of problems such as soaring material costs, increased driving complexity, and intensified heat dissipation pressure; existing light homogenization technologies mostly rely on random scattering particles or simple microstructures, lacking spatial correspondence with the LED array, resulting in low light efficiency; more seriously, ordinary optical materials are prone to yellowing and cracking in the high-temperature and high-humidity environment of automotive applications, causing brightness decay and color shift, directly affecting driving safety. Although some patents mention microstructure or dot matrix technology, none of them have broken through the limitations of single-point optimization and have not established a deep coupling system of customized microstructure-gradient dots-automotive-grade materials. Therefore, the industry urgently needs a full-chain innovation solution that integrates optical design, intelligent algorithms and materials science to achieve synergistic breakthroughs in ultra-thinness, high uniformity and cost reduction while ensuring automotive-grade reliability. Summary of the Invention

[0003] This invention provides a Mini LED backlight and its design optimization method to solve the problems mentioned in the background section above: This invention proposes a design optimization method for a Mini LED backlight, the method comprising: S1. To meet the ultra-thin requirements of automotive Mini LED backlights, the substrate of the diffuser plate is customized and selected, and optical materials with high light transmittance, high weather resistance and low yellowing are selected. Based on different lamp spacing scenarios in the vehicle, a customized microstructure array is constructed at the position of each LED bead on the diffuser plate to form a microlens / microprism composite structure that is precisely matched with the spatial distribution of LEDs, thus completing the initial uniform light optical foundation construction. S2. Based on the optical diffusion effect feedback data of the customized microstructure array, a surface gradient white oil dot printing process is developed; the dot arrangement density, shape and printing accuracy are dynamically optimized through intelligent algorithms to form a gradient dot layer deeply coupled with the microstructure. S3. Based on the simulated optical parameters of the composite uniform light structure, iteratively optimize the microstructure geometric parameters and dot arrangement algorithm to reduce the module's optical depth; simultaneously adjust the LED bead layout. S4. The composite light diffuser plate is subjected to automotive-grade reliability enhancement treatment. The yellowing coefficient is controlled to ≤1.5 through material modification. The AEC-Q100 full-item environmental test is completed. The internal stress distribution structure of the diffuser plate is optimized based on the test results. S5. Establish a large-scale mass production process system, develop high-precision microstructure injection molding process, gradient dot printing positioning technology and UV curing energy control system; establish full-process quality control standards to achieve stable batch application of composite uniform light diffusion plates in automotive Mini LED backlight products.

[0004] This invention proposes a Mini LED backlight, which is designed and optimized based on any of the design optimization methods described above.

[0005] The beneficial effects of this invention are as follows: By employing a composite light-uniformation technology combining customized microstructure arrays and gradient dot printing, the brightness uniformity of the image is significantly improved to over 90%, while the module's OD value is reduced by over 40%, perfectly meeting the requirements of ultra-thin automotive designs. This method reduces the number of LED chips by more than 25%, significantly lowering material costs and driving complexity. Furthermore, intelligent algorithms optimize luminous efficiency, effectively alleviating heat dissipation pressure. Automotive-grade material modification technology ensures the diffuser's yellowing coefficient is ≤1.5, maintaining stable optical performance even after rigorous AEC-Q100 environmental testing, avoiding brightness decay and color shift issues caused by yellowing and cracking, thus effectively guaranteeing driving safety. The establishment of a large-scale mass production process system and comprehensive quality control standards ensures product yield and production efficiency, enabling rapid response to the diverse needs of the automotive market and driving Mini LED backlight technology towards breakthroughs in performance, cost, and reliability. Attached Figure Description

[0006] Figure 1 This is a diagram illustrating the steps of the method described in this invention. Detailed Implementation

[0007] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0008] One embodiment of the present invention, such as Figure 1 As shown, a design optimization method for a Mini LED backlight includes: S1. To meet the ultra-thin requirements of automotive Mini LED backlights, the substrate material of the diffuser plate is customized and selected with high light transmittance, high weather resistance, and low yellowing. Based on different lamp spacing scenarios in the vehicle (P5-P10), a customized microstructure array is constructed at the position of each LED bead on the diffuser plate to form a microlens / microprism composite structure that is precisely matched with the spatial distribution of the LEDs, thus completing the initial uniform light optical foundation construction. S2. Based on the optical diffusion effect feedback data of the customized microstructure array, a surface gradient white oil dot printing process is developed; through intelligent algorithms, the dot arrangement density, shape and printing accuracy are dynamically optimized to form a gradient dot layer deeply coupled with the microstructure, thereby achieving secondary light uniform optimization and eliminating residual lamp eye spots and yellow edge problems. S3. Based on the simulated optical parameters of the composite uniform light structure, the composite uniform light structure is a customized microstructure + gradient dots. The geometric parameters of the microstructure and the dot arrangement algorithm are iteratively optimized to reduce the optical depth (OD value) of the module by more than 40%. The layout of the LED beads is adjusted simultaneously to reduce the amount of LED beads by more than 25% while maintaining the uniformity of screen brightness ≥90%, thus balancing cost and performance. S4. The composite light diffuser plate is subjected to automotive-grade reliability enhancement treatment. The yellowing coefficient is controlled to ≤1.5 through material modification. The AEC-Q100 full-item environmental test is completed. The full-item environmental test includes temperature cycling from -40℃ to 85℃, 1000h damp heat and vibration shock. Based on the test results, the internal stress distribution structure of the diffuser plate is optimized to improve crack resistance. S5. Establish a large-scale mass production process system, develop high-precision microstructure injection molding process, gradient dot printing positioning technology and UV curing energy control system; establish full-process quality control standards to achieve stable batch application of composite uniform light diffusion plates in automotive Mini LED backlight products.

[0009] The working principle of the above technical solution is as follows: In the initial optical construction stage, a requirement database is first established by summarizing the usage conditions of various automotive scenarios. High-quality optical substrates suitable for long-term automotive operating conditions are then selected based on multi-dimensional performance screening. Next, the application range of all lamp spacing specifications is divided, the lamp bead positions and distribution density are calibrated, and the spatial correspondence between the lamp beads and the diffuser plate is established. Subsequently, work units are divided in the corresponding areas of the lamp beads, and the microlens basic structure is constructed layer by layer. Microprism units are stacked to form a composite array. The structural height, spacing, and surface curvature are adjusted sequentially to allow the light emitted from the point light source to undergo initial dispersion and directional transmission on the diffuser plate surface. Finally, the structural details are calibrated through optical verification to solidify the basic light uniformity of the backlight source, weakening the optical defects caused by direct point light source illumination from the source. In the secondary light uniformity optimization stage, the light field direction, scattering angle, and light spot distribution information of the previous microstructure array are collected throughout the process and integrated to form complete optical feedback data. Simultaneously, the white oil ink components are adjusted to improve coating adhesion and environmental tolerance, adapting to the alternating temperature and humidity environment of the vehicle. Based on feedback data, a dot matrix calculation model is built, sequentially performing step-by-step calculations on dot density, dot position, and size specifications. The results of multiple calculations are integrated to output a precise dot matrix layout. Strict control of printing speed and pressure, combined with UV curing, ensures dot matrix shaping, forming a uniform and stable gradient dot layer. Utilizing the dual-layer optical superposition of the microstructure array and gradient dot layer, light undergoes secondary scattering compensation, gradually weakening localized strong light areas and completely eliminating lamp glare and yellow edge defects. During the optical parameter iteration and power reduction phase, key indicators such as optical depth and brightness uniformity of the composite uniform light structure are continuously collected, and parameter fluctuation patterns are recorded over a long period to build a performance database. The microstructure geometry and dot matrix layout are adjusted step-by-step, and multiple sets of optical tests are used to compare actual performance, continuously enhancing light dispersion efficiency. The dynamic changes in optical depth are continuously tracked, and through multiple rounds of parameter fine-tuning, the indicators are controlled within the range corresponding to automotive ultra-thin designs, preserving the original display quality unaffected by modifications. Under the premise of stable and highly uniform display effect, the spacing and number of LED beads were adjusted, the performance retention after reduction was calculated, and the balance between material input and optical output was compared. Without reducing the quality of automotive display, the consumption of LED beads was reduced, alleviating the heat dissipation burden of the backlight module. In the automotive-grade reliability enhancement stage, the aging characteristics of the diffuser plate substrate and surface ink were improved through molecular structure modification to suppress yellowing and aging phenomena during long-term use. Three extreme working condition tests were carried out in sequence: high and low temperature cycling, long-term damp heat static placement, and vibration and shock simulation, and the changes in the appearance and optical performance of the board under different environments were fully recorded. Multi-dimensional test data were summarized to identify stress concentration and weak areas in the board. The interlayer bonding tightness and internal support structure were adjusted in a targeted manner to improve the stress distribution of the board, enhance the interlayer bonding strength and overall resistance to deformation and cracking, so that the diffuser plate can adapt to the complex driving conditions of the vehicle for a long time.During the mass production phase, the entire production process was streamlined based on the results of previous trials, clarifying the standards for each step and establishing a standardized operating procedure that can be replicated in batches. The operating parameters of the core equipment for injection molding, printing, and curing were individually adjusted, and the equipment's operating accuracy was calibrated to ensure batch consistency in microstructure molding dimensions, dot printing positions, and curing effects. A comprehensive testing system was established, encompassing raw material warehousing, process inspections, and finished product acceptance, incorporating optical and weather resistance indicators into routine testing. Relying on a mature process system and quality control rules, continuous mass production of composite light diffusion plates was achieved, ensuring consistent and stable performance across different batches. Ultimately, this enabled the routine application of this type of backlight component in multiple automotive display products.

[0010] The effects of the above technical solution are as follows: By customizing the selection of the diffuser plate substrate and matching the position of the LED beads to construct a composite microstructure, the initial backlight uniformity efficiency can be improved, the optical stability and weather resistance of the substrate can be enhanced, and light transmission loss can be reduced; by deeply coupling the gradient white oil dots with the microstructure to form a composite uniform light structure, the uniformity of screen brightness can be improved, the problems of lamp eye spots and yellow edges on the screen can be eliminated, and the effect of uneven local light intensity on the display effect can be avoided; by iteratively optimizing the parameters of the composite uniform light structure, the optical depth of the module can be reduced by more than 40%, the amount of LED beads can be reduced by more than 25%, the material cost and heat dissipation pressure can be reduced, and the thickness can be avoided from being too large to adapt to the ultra-thin automotive scenario; by carrying out material modification and automotive-grade reliability testing on the diffuser plate, the yellowing coefficient of the material can be reduced, the structural crack resistance and environmental aging resistance can be enhanced, and the performance degradation under complex automotive conditions can be avoided; by building a high-precision mass production process and a full-process quality control system, the consistency of product batches can be improved, the stability of mass application can be guaranteed, and the needs of large-scale automotive assembly can be met while maintaining excellent optical and reliability performance.

[0011] In one embodiment of the present invention, S1 includes: S11. Comprehensively collect application indicators of automotive Mini LED backlight in scenarios of large screen, ultra-thin and high uniformity, summarize the adaptation conditions corresponding to different car models and display sizes, and organize them into a complete scenario requirement database. S12. Select a variety of optical substrate samples to conduct multi-dimensional performance testing, continuously monitor transmittance, weather resistance and anti-yellowing index, compare the performance degradation of different substrates under extreme environments, and finally screen out high-quality substrates that meet the requirements for long-term use in vehicles. S13. Divide the application ranges corresponding to the lamp spacing of the entire series from P5 to P10, mark the point coordinates and distribution density of LED beads in each range, count the light field coverage range under different lamp spacings, and establish the spatial correspondence between the lamp beads and the diffuser plate. S14. At the points on the surface of the diffuser plate that are precisely matched with the LED beads, an array structure of microlenses and microprisms is constructed layer by layer. The height spacing and curvature parameters of the structure are adjusted to allow the light to be initially dispersed and guided in the early stage of transmission. S15. Perform optical effect verification on the completed array structure, detect the degree of light dispersion and the state of light spot suppression, adjust the structural details to achieve the expected initial uniform light state, and form a diffuser substrate structure with stable basic optical capabilities.

[0012] The working principle and effects of the above technical solution are as follows: By comprehensively collecting automotive application indicators and forming a scenario requirement database, it is possible to accurately match the usage conditions of different vehicle models and display sizes, improve the fit between subsequent R&D and actual application, and avoid the R&D direction deviating from the actual use needs of vehicles; By screening high-quality optical substrates through multi-dimensional testing, it is possible to improve the light transmittance and weather resistance of the diffuser plate, reduce the probability of yellowing after long-term use, reduce performance degradation in extreme environments, and avoid the impact of unqualified substrates on the overall lifespan of the backlight; By dividing the lamp spacing interval and establishing the spatial correspondence between the lamp beads and the diffuser plate, it is possible to adapt to a full range of lamp spacing application scenarios, improve the structural matching accuracy, and reduce light transmission deviation; By constructing a combination array of microlenses and microprisms and adjusting the parameters, it is possible to improve the initial light dispersion and guiding efficiency, enhance the basic light uniformity effect, and reduce the pressure of subsequent light uniformity processing; By verifying the optical effect and adjusting the structural details, it is possible to stabilize the initial light uniformity state, improve the reliability of the diffuser plate substrate structure, meet the requirements of ultra-thin applications, and provide a solid foundation for subsequent optical optimization.

[0013] In one embodiment of the present invention, step S14 includes: S141. Position the working area on the surface of the diffuser plate that matches the LED beads, divide the working unit of the structure within the area, and generate the structural area that matches the LED bead position. S142. Carry out the layered construction of the microlens structure within the structural construction area, control the thickness of the single layer and the curvature of the surface layer, and generate the basic structure layer of the microlens. S143. Superimpose microprism structures on the microlens basic structure layer, arrange the orientation and combination of prism units, and generate a composite array layer of microlenses and microprisms. S144. Adjust the overall height of the unit structure in the composite array layer, control the spacing between adjacent structures, and match the light emission direction and transmission path of the lamp beads. S145. Adjust the curvature of the composite array layer unit structure to guide the light to complete the initial transmission inside the diffuser plate, forming an initial light dispersion and guidance state.

[0014] The working principle and effects of the above technical solution are as follows: By accurately positioning the matching area of ​​the LED beads and dividing the structural construction work units, the alignment accuracy of the structural construction can be improved, avoiding the impact of the construction area offset on the light transmission effect; by constructing the microlens structure in layers and controlling the thickness and curvature, the lateral diffusion capability of the point light source can be enhanced, the uniformity of the initial light divergence can be improved, and the situation of excessive concentration of central light intensity can be reduced; by superimposing the microprism structure on the microlens layer, the longitudinal spreading effect of light can be improved, the integrity of the light field distribution can be enhanced, and the uniformity defects caused by a single structure can be avoided; by adjusting the height of the composite array and the adjacent spacing, the light emission direction of the LED beads can be accurately matched, the light transmission loss can be reduced, and the problem of insufficient or overlapping light field coverage can be avoided; by adjusting the curvature of the composite array surface, the light can be smoothly guided to conduct within the plate, forming a stable initial dispersion guiding state, which can not only reduce the burden on subsequent secondary uniformity, but also reduce the dependence on high optical depth from the source.

[0015] In one embodiment of the present invention, S2 includes: S21. Collect information such as the light field transmission path, light spot distribution range and light scattering angle of the microstructure array obtained in S1 throughout the process, and summarize them to form complete optical effect feedback data; S22. Repeatedly adjust the proportions of various components of white ink to improve the adhesion strength and environmental resistance of the ink on the microstructure surface, so that the ink does not peel off or change color in the high and low temperature alternating environment, and is suitable for the complex use environment of the vehicle. S23. Build a dedicated dot layout calculation model, input optical effect feedback data to complete the calculation of dot density, position and size, generate a dot layout scheme that is highly adapted to the microstructure, and ensure that the dots and microstructure work together. S24. Printing operation is carried out according to the layout scheme generated by the calculation, and the printing speed and pressure are precisely controlled. Then, UV curing is used to complete the dot setting and form a uniform and stable gradient white oil dot layer on the surface of the microstructure. S25. By integrating the optical effects of the microstructure layer and the gradient dot layer, light is dispersed and guided twice, eliminating local light concentration and completing the composite uniform light structure construction, thus improving the overall uniform light effect.

[0016] The working principle and effects of the above technical solution are as follows: By collecting light field transmission and scattering information throughout the process and forming optical effect feedback data, the optical performance of the microstructure array can be accurately grasped, reducing the blindness of subsequent process adjustments and avoiding poor light uniformity caused by parameter deviations; by optimizing the proportion of white ink components, the adhesion strength and environmental tolerance of the ink on the surface of the microstructure can be improved, avoiding ink peeling and discoloration under high and low temperature alternating environments, and extending the stable service life of the diffuser plate; by building a dot arrangement calculation model and generating an adaptation scheme, the synergistic effect of the dots and microstructures can be improved, the accuracy of light field compensation can be increased, and display defects caused by local light intensity imbalance can be reduced; by precisely controlling the printing and UV curing parameters, the uniformity and stability of the gradient dot layer can be guaranteed, avoiding dot offset or insufficient curing from affecting optical performance; by integrating the optical effects of the microstructure and the dot layer, secondary light uniformity optimization can be completed, eliminating local light concentration and spot problems, which can not only significantly improve the overall light uniformity quality, but also create conditions for subsequent reduction of optical depth and reduction of LED beads.

[0017] In one embodiment of the present invention, step S23 includes: Load optical effect feedback data, construct the basic environment for dot matrix layout calculation, and generate the initial state of the calculation model; Import light field transmission parameters into the computational model to drive the model to complete the numerical calculation of dot density and generate dot density distribution data; The density distribution data is combined to complete the calculation and matching of the dot locations, and the dot location distribution data on the surface of the diffuser plate is output. Based on the point distribution data, iterative calculations of the dot size are performed to output dot specification data that adapts to the light field conduction requirements; the calculation results of density, location and specification are integrated to output a dot layout scheme that is highly adapted to the microstructure.

[0018] The working principle and effects of the above technical solution are as follows: By loading optical effect feedback data and constructing a computational foundation environment, the dot arrangement calculation can maintain a stable operating state, reduce computational deviations, and avoid solution failure due to data loss; by importing light field transmission parameters and completing dot density calculation, the rationality of density distribution can be improved, the risk of local light intensity imbalance can be reduced, and the light compensation can be kept in a balanced state; by combining density data to complete dot position matching calculation, the alignment accuracy between dot and microstructure can be improved, and the effect of dot misalignment on the synergistic light uniformity effect can be avoided; by iteratively calculating the dot size and outputting adaptive specification data, the dot can better match the light field transmission requirements and enhance the fineness of light dispersion; by integrating multiple types of calculation results to output an adaptive arrangement scheme, the overall coordination of the composite light uniformity structure can be improved, which can not only give full play to the superposition effect of microstructure and dot, but also provide reliable support for eliminating light spots and yellow edges.

[0019] In one embodiment of the present invention, S3 includes: S31. Extract core parameters such as optical depth, brightness uniformity, and spot suppression effect of composite uniform light structure, record the real-time values ​​and trends of each parameter, and form a complete optical performance parameter database to provide data support for iterative optimization. S32. Gradually adjust the geometric shape and dot arrangement rules of the microstructure, repeatedly test the optical performance under different parameter combinations, continuously optimize the light dispersion ability of the composite uniform light structure, and continuously reduce the optical depth value of the module. S33. Continuously monitor the changes in the optical depth of the module, and reduce the optical depth to the target range through multiple rounds of testing and adjustment to meet the design requirements of ultra-thin automotive backlights without affecting the overall optical display effect; S34. Readjust the arrangement spacing and assembly quantity of LED beads. While ensuring that the uniformity of screen brightness is at a stable and high level, gradually reduce the number of beads used and calculate the reduction ratio and performance maintenance status. S35. By comprehensively comparing the matching relationship between the amount of LED chips and optical performance, and balancing production costs and display effects, a backlight module configuration scheme that takes into account both cost control and performance stability is formed.

[0020] The working principle and effects of the above technical solution are as follows: By extracting the core parameters of the composite uniform light structure and establishing an optical performance parameter database, the parameter change trend can be fully recorded, providing a real basis for iterative optimization and avoiding fluctuations in performance caused by a lack of data support during the optimization process; by adjusting the microstructure morphology and dot arrangement rules and conducting repeated tests, the light dispersion capability can be continuously enhanced, gradually reducing the optical depth of the module and reducing the dependence on high thickness in traditional solutions; by continuously monitoring the optical depth and completing multiple rounds of adjustments, the value can be stabilized within the target range, meeting the conditions for ultra-thin automotive applications and avoiding the impact of excessive thickness on vehicle assembly; by optimizing the spacing of LED beads and reducing the number used, material costs and heat dissipation load can be reduced while maintaining high brightness uniformity, avoiding resource waste and heat accumulation; by balancing the number of LED beads and optical performance, a stable and reliable module configuration solution can be formed, which can not only ensure display quality but also improve product cost-effectiveness and enhance the adaptability and market competitiveness of automotive scenarios.

[0021] In one embodiment of the present invention, S32 includes: The optical performance parameters of the composite homogenizing structure are imported, and the geometric morphology of the microstructure is adjusted step by step to generate the composite homogenizing structure after morphological adjustment. Based on the composite uniform light structure after morphological adjustment, the dot layout rules are adjusted synchronously to generate dot layout data with updated rules. Optical performance tests were conducted on the adjusted composite uniform light structure and dot arrangement data, and relevant test data on light dispersion were collected. Based on the test data related to light dispersion, the light dispersion effect of the composite uniform light structure is optimized, and the optimized light dispersion result is generated. Based on the light dispersion optimization results, the module's optical depth value is continuously reduced to generate optical depth optimization data.

[0022] The working principle and effects of the above technical solution are as follows: By importing optical performance parameters and adjusting the geometry of the microstructure step by step, the light adaptability of the composite uniform light structure can be improved, light transmission loss can be reduced, and the uniform light efficiency can be avoided due to unreasonable shape. By synchronously updating the dot arrangement rules and generating new arrangement data, the synergistic effect between the microstructure and the dots can be strengthened, the uniformity of the light field distribution can be improved, and the matching deviation between the two can be avoided from affecting the overall optical performance. By conducting optical performance tests on the adjusted structure and collecting relevant data, the light dispersion state can be accurately reflected, the subjective bias in the optimization process can be reduced, and the performance fluctuation caused by blind adjustment can be avoided. By optimizing the light dispersion effect based on the test data, the backlight uniform light quality can be further improved and the problem of uneven local light intensity can be eliminated. By continuously reducing the optical depth of the module and generating optimized data, the thickness of the backlight module can be effectively reduced, which can meet the requirements of ultra-thin automotive assembly and provide sufficient space for subsequent reduction of LED chips.

[0023] In one embodiment of the present invention, S33 includes: The composite light-monitoring structure with adjusted parameters is tracked throughout the entire process, and information on optical depth changes during module operation is collected to generate a continuous optical depth monitoring dataset. The continuous optical depth monitoring dataset is segmented and statistically compared to summarize the fluctuation patterns of optical depth under different adjustment conditions and generate characteristic information of optical depth changes. The backlight module display effect was tested by combining optical depth change feature information, and data related to screen uniformity and spot suppression status were collected. Based on the display effect test data, parameter closed-loop correction is carried out, and the relevant conditions of the composite uniform light structure are continuously fine-tuned to reduce the gap between the optical depth and the target range. Maintain the optical depth stable within the target range, preserve the complete state of the image display effect, and generate qualified optical depth data that meets the requirements of ultra-thin automotive scenarios.

[0024] The working principle and effects of the above technical solution are as follows: By tracking the composite uniform light structure throughout the process and collecting information on optical depth changes, the real state of the module adjustment process can be fully grasped, avoiding deviations in optimization direction caused by data loss; by segmenting and statistically monitoring data and summarizing depth fluctuation patterns, the actual impact of parameter adjustments can be accurately identified, reducing ineffective debugging steps and lowering resource consumption in the optimization process; by combining fluctuation patterns to conduct display effect testing, both optical depth and image performance can be considered simultaneously, avoiding uniformity reduction or spot recurrence caused by simply reducing thickness; by performing closed-loop correction based on detection data, the gap between optical depth and the target range can be continuously narrowed, improving the accuracy of parameter adjustments and preventing repeated debugging from affecting R&D efficiency; by stabilizing the optical depth within the target range and retaining the complete display effect, qualified data adapted to automotive ultra-thin designs can be generated, which can meet the assembly requirements of automotive products and continuously maintain excellent optical output.

[0025] In one embodiment of the present invention, step S4 includes: S41. Conduct targeted material modification treatment on the composite light diffusion plate to optimize the molecular structure of the substrate and ink, control the degree of yellowing after long-term use of the product, and keep the yellowing coefficient within the range that meets automotive-grade requirements. S42. Place the diffuser plate in a high and low temperature cycling environment from -40℃ to 85℃ and conduct continuous multi-cycle tolerance tests. Record the changes in the optical performance and structural morphology of the product under different cycles to evaluate its high and low temperature adaptability. S43. Place the diffuser plate in a high humidity environment for 1000 consecutive hours of exposure testing, monitor the performance degradation of the product surface and interior, check for problems such as yellowing, cracking, and deformation, and ensure stability in humid and hot environments. S44. Apply vibration and impact loads corresponding to the vehicle scenario to the diffuser plate to simulate the vibration state during vehicle operation, test the structural strength and damage resistance of the product, and ensure that no damage or failure occurs during vehicle use. S45. Analyze all test data to identify weak points in the structure, adjust the interlayer bonding method and support structure inside the diffuser plate, improve the interlayer bonding strength and crack resistance, and form a highly stable composite light diffusion plate product.

[0026] The working principle and effects of the above technical solution are as follows: By modifying the composite light-diffusing plate, the molecular structure of the substrate and ink can be optimized, reducing the degree of yellowing after long-term use and avoiding the degradation of optical performance over time; by conducting high and low temperature cycle tolerance tests, the temperature adaptability of the diffuser plate can be fully evaluated, reducing structural deformation under extreme temperatures and avoiding performance failure in the temperature difference environment of the vehicle; by conducting long-term humid and hot environment exposure tests, the weather resistance of the diffuser plate can be identified in advance, avoiding yellowing, cracking or deformation under high humidity conditions and ensuring long-term stability; by applying vibration and impact loads to simulate vehicle conditions, the structural strength of the diffuser plate can be tested, avoiding damage caused by vehicle vibration and improving vehicle safety; by analyzing test data and optimizing interlayer bonding and support structure, the crack resistance of the diffuser plate can be improved, reducing the failure risk caused by structural weak points, which can not only meet automotive-grade reliability standards, but also enable the composite light-diffusing plate to maintain long-term stable operation in complex vehicle environments.

[0027] In one embodiment of the present invention, S45 includes: A comprehensive performance analysis dataset is generated by summarizing multiple test data of vibration and shock in high and low temperature cyclic humid heat environment. By comparing each item in the comprehensive performance analysis dataset, we can identify the weaker areas in the diffuser plate structure and generate information on the structural weak points. Optimize the interlayer bonding state inside the diffuser plate based on information about structural weak points, improve the tightness of interlayer connections, and generate interlayer bonding reinforcement data; Based on the interlayer bonding reinforcement data, the internal support structure of the diffusion plate is modified to enhance the overall deformation resistance of the structure and generate structural support reinforcement data. By integrating and strengthening the interlayer state and support structure, the overall crack resistance of the diffuser plate is improved, resulting in a high-stability composite light diffusion plate product.

[0028] The working principle and effects of the above technical solution are as follows: By summarizing multiple test data to generate a comprehensive performance analysis dataset, the real performance of the diffuser plate under different automotive operating conditions can be fully grasped, avoiding the one-sidedness of single test data and preventing the omission of potential structural hazards; by comparing and analyzing the dataset item by item and identifying structural weak points, performance shortcomings can be accurately located, reducing the waste of resources caused by blind optimization and avoiding poor reliability improvement due to the inability to find the root cause of the problem; by optimizing the interlayer bonding state for weak points, the tightness of interlayer connection can be improved, reducing the risk of interlayer separation and avoiding delamination failure under complex automotive operating conditions; by modifying the internal support structure and enhancing the deformation resistance, the overall structural strength of the diffuser plate can be improved, reducing deformation cracking caused by external impact or environmental changes and extending the product's service life; by integrating the reinforced interlayer and support structure, the crack resistance of the diffuser plate can be significantly improved, forming a highly stable finished product that can meet the requirements of long-term use in automotive applications and ensure the long-term stability of composite light uniformity, avoiding the impact of structural failure on backlight display quality.

[0029] In one embodiment of the present invention, step S5 includes: S51. Combining R&D results with production conditions, plan the entire production path of composite light diffusion plates, clarify the operation standards and connection processes of each link, form a standardized and replicable mass production process, and ensure production efficiency and product consistency. S52. Thoroughly debug the operating parameters of the microstructure injection molding equipment, control key indicators such as temperature, pressure, and speed, ensure the dimensional accuracy and surface finish of the microstructure processing, and keep the structure of each diffuser plate uniform. S53. Continuously optimize the dot printing positioning accuracy and UV curing energy parameters, calibrate the operating status of printing and curing equipment, stabilize the operation quality of printing and curing processes, and avoid problems such as dot offset and incomplete curing. S54. Develop a full-process testing standard covering raw material intake, intermediate product testing, and final product acceptance, and include optical performance reliability indicators in the testing scope to ensure that each batch of products meets the requirements for vehicle use. S55. We officially implemented standardized mass production processes and a full-process quality control system, completed the large-scale mass production of composite light diffusion plates, and stably applied the products to multiple automotive Mini LED backlight products.

[0030] The working principle and effects of the above technical solution are as follows: By standardizing the mass production process, the production efficiency of composite light diffusion plates is improved, production process loopholes are reduced, and capacity waste caused by process chaos is avoided. Optimizing equipment operating parameters improves the processing accuracy of microstructures and dots, reducing the occurrence of problems such as dimensional deviations and incomplete curing. Establishing a full-process testing standard enhances product quality stability, reduces the yield of defective products, and avoids the impact of quality issues on batch applications. Implementing a standardized management and control system ensures consistent performance of each batch of products while enabling large-scale mass production and reducing resource consumption during the production process. It can meet the batch supply needs of automotive Mini LED backlight products while ensuring stable product optical performance, avoiding quality degradation due to increased mass production scale, and further improving the market adaptability and application stability of the products.

[0031] In one embodiment of the present invention, a Mini LED backlight is provided, wherein the Mini LED backlight is designed and optimized based on any of the design optimization methods described above.

[0032] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A design optimization method for a Mini LED backlight, characterized in that, The method includes: S1. To meet the ultra-thin requirements of automotive Mini LED backlights, the substrate of the diffuser plate is customized and selected, and optical materials with high light transmittance, high weather resistance and low yellowing are selected. Based on different lamp spacing scenarios in the vehicle, a customized microstructure array is constructed at the position of each LED bead on the diffuser plate to form a microlens / microprism composite structure that is precisely matched with the spatial distribution of LEDs, thus completing the initial uniform light optical foundation construction. S2. Based on the optical diffusion effect feedback data of the customized microstructure array, a surface gradient white oil dot printing process is developed; the dot arrangement density, shape and printing accuracy are dynamically optimized through intelligent algorithms to form a gradient dot layer deeply coupled with the microstructure. S3. Based on the simulated optical parameters of the composite uniform light structure, iteratively optimize the microstructure geometric parameters and dot arrangement algorithm to reduce the module's optical depth; simultaneously adjust the LED bead layout. S4. The composite light diffuser plate is subjected to automotive-grade reliability enhancement treatment. The yellowing coefficient is controlled to ≤1.5 through material modification. The AEC-Q100 full-item environmental test is completed. The internal stress distribution structure of the diffuser plate is optimized based on the test results. S5. Establish a large-scale mass production process system, develop high-precision microstructure injection molding process, gradient dot printing positioning technology and UV curing energy control system; establish full-process quality control standards to achieve stable batch application of composite uniform light diffusion plates in automotive MiniLED backlight products.

2. The design optimization method for a Mini LED backlight according to claim 1, characterized in that, S1 includes: S11. Comprehensively collect application indicators of automotive Mini LED backlight in scenarios of large screen, ultra-thin and high uniformity, summarize the adaptation conditions corresponding to different car models and display sizes, and organize them into a complete scenario requirement database. S12. Select a variety of optical substrate samples to conduct multi-dimensional performance testing, continuously monitor transmittance, weather resistance and anti-yellowing index, compare the performance degradation of different substrates under extreme environments, and finally screen out high-quality substrates that meet the requirements for long-term use in vehicles. S13. Divide the application ranges corresponding to the lamp spacing of the entire series from P5 to P10, mark the point coordinates and distribution density of LED beads in each range, count the light field coverage range under different lamp spacings, and establish the spatial correspondence between the lamp beads and the diffuser plate. S14. At the points on the surface of the diffuser plate that are precisely matched with the LED beads, an array structure of microlenses and microprisms is constructed layer by layer. The height spacing and curvature parameters of the structure are adjusted to allow the light to be initially dispersed and guided in the early stage of transmission. S15. Perform optical effect verification on the completed array structure, detect the degree of light dispersion and the state of light spot suppression, adjust the structural details to achieve the expected initial uniform light state, and form a diffuser substrate structure with stable basic optical capabilities.

3. The design optimization method for a Mini LED backlight according to claim 2, characterized in that, S14 includes: S141. Position the working area on the surface of the diffuser plate that matches the LED beads, divide the working unit of the structure within the area, and generate the structural area that matches the LED bead position. S142. Carry out the layered construction of the microlens structure within the structural construction area, control the thickness of the single layer and the curvature of the surface layer, and generate the basic structure layer of the microlens. S143. Superimpose microprism structures on the microlens basic structure layer, arrange the orientation and combination of prism units, and generate a composite array layer of microlenses and microprisms. S144. Adjust the overall height of the unit structure in the composite array layer, control the spacing between adjacent structures, and match the light emission direction and transmission path of the lamp beads. S145. Adjust the curvature of the composite array layer unit structure to guide the light to complete the initial transmission inside the diffuser plate, forming an initial light dispersion and guidance state.

4. The design optimization method for a Mini LED backlight according to claim 1, characterized in that, S2 includes: S21. Collect information about the microstructure array obtained in S1 throughout the entire process and summarize it to form complete optical effect feedback data; S22. Repeatedly adjust the proportions of various components of white ink to improve the adhesion strength and environmental resistance of the ink on the microstructure surface, so that the ink does not peel off or change color in the high and low temperature alternating environment, and is suitable for the complex use environment of the vehicle. S23. Build a dedicated dot layout calculation model, input optical effect feedback data to complete the calculation of dot density, position and size, and generate a dot layout scheme that is highly adapted to the microstructure. S24. Printing operation is carried out according to the layout scheme generated by the calculation, and the printing speed and pressure are precisely controlled. Then, UV curing is used to complete the dot setting and form a uniform and stable gradient white oil dot layer on the surface of the microstructure. S25. The optical effects of the integrated microstructure layer and gradient dot layer allow light to pass through two dispersion and guidance processes, eliminating local light aggregation and completing the composite uniform light structure construction.

5. The design optimization method for a Mini LED backlight according to claim 4, characterized in that, S23 includes: Load optical effect feedback data, construct the basic environment for dot matrix layout calculation, and generate the initial state of the calculation model; Import light field transmission parameters into the computational model to drive the model to complete the numerical calculation of dot density and generate dot density distribution data; The density distribution data is combined to complete the calculation and matching of the dot locations, and the dot location distribution data on the surface of the diffuser plate is output. Based on the point distribution data, iterative calculations of the dot size are performed to output dot specification data that adapts to the light field conduction requirements; the calculation results of density, location and specification are integrated to output a dot layout scheme that is highly adapted to the microstructure.

6. The design optimization method for a Mini LED backlight according to claim 1, characterized in that, The S3 includes: S31. Extract all core parameters of the composite uniform light structure, record the real-time values ​​and trends of each parameter, and form a complete database of optical performance parameters. S32. Gradually adjust the geometric shape and dot arrangement rules of the microstructure, repeatedly test the optical performance under different parameter combinations, continuously optimize the light dispersion ability of the composite uniform light structure, and continuously reduce the optical depth value of the module. S33. Continuously monitor the changes in the optical depth of the module, and reduce the optical depth to the target range through multiple rounds of testing and adjustment to meet the design requirements of ultra-thin automotive backlights without affecting the overall optical display effect; S34. Readjust the arrangement spacing and assembly quantity of LED beads. While ensuring that the uniformity of screen brightness is at a stable and high level, gradually reduce the number of beads used and calculate the reduction ratio and performance maintenance status. S35. By comprehensively comparing the matching relationship between the amount of LED chips and optical performance, and balancing production costs and display effects, a backlight module configuration scheme that takes into account both cost control and performance stability is formed.

7. The design optimization method for a Mini LED backlight according to claim 6, characterized in that, S32 includes: The optical performance parameters of the composite homogenizing structure are imported, and the geometric morphology of the microstructure is adjusted step by step to generate the composite homogenizing structure after morphological adjustment. Based on the composite uniform light structure after morphological adjustment, the dot layout rules are adjusted synchronously to generate dot layout data with updated rules. Optical performance tests were conducted on the adjusted composite uniform light structure and dot arrangement data, and relevant test data on light dispersion were collected. Based on the test data related to light dispersion, the light dispersion effect of the composite uniform light structure is optimized, and the optimized light dispersion result is generated. Based on the light dispersion optimization results, the module's optical depth value is continuously reduced to generate optical depth optimization data.

8. The design optimization method for a Mini LED backlight according to claim 1, characterized in that, The S4 includes: S41. Conduct targeted material modification treatment on the composite light diffusion plate to optimize the molecular structure of the substrate and ink, control the degree of yellowing after long-term use of the product, and keep the yellowing coefficient within the range that meets automotive-grade requirements. S42. Place the diffuser plate in a high and low temperature cycling environment from -40℃ to 85℃ and conduct continuous multi-cycle tolerance tests. Record the changes in the optical performance and structural morphology of the product under different cycles to evaluate its high and low temperature adaptability. S43. Place the diffuser plate in a high humidity environment for 1000 consecutive hours of exposure testing to monitor the performance degradation of the product surface and interior. S44. Apply vibration and impact loads corresponding to the vehicle scenario to the diffuser plate to simulate the vibration state during vehicle operation and test the structural strength and damage resistance of the product. S45. Analyze all test data to identify weak points in the structure, adjust the interlayer bonding method and support structure of the diffuser plate to form a highly stable composite light diffusion plate.

9. The design optimization method for a Mini LED backlight according to claim 1, characterized in that, The S5 includes: S51. Combining R&D results with production conditions, plan the entire production path of composite light diffusion plates, clarify the operation standards and connection processes of each link, and form a standardized and replicable mass production process. S52. Thoroughly debug the operating parameters of the microstructure injection molding equipment, control key indicators, ensure the dimensional accuracy and surface finish of the microstructure processing, and keep the structure of each diffuser plate uniform. S53. Continuously optimize the dot printing positioning accuracy and UV curing energy parameters, calibrate the operating status of printing and curing equipment, and stabilize the work quality of printing and curing processes. S54. Develop a full-process testing standard covering raw material intake, intermediate product testing, and final product acceptance, and include optical performance reliability indicators in the testing scope. S55. We officially implemented standardized mass production processes and a full-process quality control system, completed the large-scale mass production of composite light diffusion plates, and stably applied the products to multiple automotive Mini LED backlight products.

10. A Mini LED backlight, characterized in that, The Mini LED backlight is designed and optimized based on the design optimization method described in any one of claims 1 to 9.

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