Annular Reflective Layer Layout for Faster Light-Emitting Substrates
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Solution Overview
Problem
The existing manufacturing processes for light-emitting substrates are inefficient due to the high cost and long preparation time of the reflective layer, which is attributed to the large area and low accuracy of the reflective sheet used.
Innovation Solution
A light-emitting substrate is designed with a reflective layer formed using a 3D printing process, featuring annular patterns arranged at intervals, and a reflective sheet with first openings that expose the annular patterns, reducing the effective area of the reflective layer and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a large area reflective sheet is used to ensure sufficient light reflection, then light reflection coverage is improved, but material cost and preparation time increase
Solution Approach 1:
The reflective layer is segmented into multiple annular patterns arranged in an array, each corresponding to a light-emitting device. This segmentation allows the reflective function to be distributed across multiple smaller units rather than requiring one large continuous reflective sheet, reducing material usage and preparation time while maintaining overall light reflection efficiency.
Solution Approach 2:
The reflective layer is positioned locally at the bottom of each annular pattern rather than covering the entire substrate area. This local quality approach places reflective material only where it is needed for light reflection, eliminating waste of material and preparation effort on areas where reflection is not required.
2Loss of energy
If a large area reflective sheet is used to ensure sufficient light reflection, then light reflection coverage is improved, but material cost increases
Solution Approach 1:
The reflective layer is divided into multiple discrete annular patterns, each serving a specific light-emitting device. This segmentation reduces the total amount of reflective material needed compared to a single large continuous sheet, as material is only applied where reflection is functionally required.
Solution Approach 2:
The reflective material is applied locally only at the bottom of each annular pattern where light reflection is needed, rather than covering the entire substrate. This local application significantly reduces material consumption and associated costs while maintaining the necessary light reflection performance.
3Loss of energy
If the reflective layer covers a large area, then light reflection is sufficient, but manufacturing precision requirements increase
Solution Approach 1:
The reflective layer is segmented into multiple independent annular patterns, each with its own positioning requirements. This segmentation reduces the cumulative positioning error that would occur with a single large continuous sheet, as each small annular pattern can be positioned and formed independently with higher precision.
Solution Approach 2:
The reflective material is applied locally to specific annular pattern regions rather than across the entire substrate. This local application reduces the total area requiring high-precision positioning and formation, making the manufacturing process more feasible and accurate.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed solution reduces the material cost and preparation time of the reflective layer, enhances the light efficiency of the light-emitting substrate, and improves the overall manufacturing efficiency of the backlight module and display apparatus.
Implementation Method 1
a reflective layer, a reflective sheet and a plurality of light-emitting devices. The reflective layer is located on a side of the substrate
Data Source
AI summary
A light-emitting substrate includes: a substrate, a reflective layer, a reflective sheet, and a plurality of light-emitting devices. The reflective layer is located on a side of the substrate, and the reflective layer has a plurality of annular patterns arranged at intervals. The reflective sheet is located on a side of the reflective layer away from the substrate, and the reflective sheet has a plurality of first openings. An annular pattern is exposed by a corresponding first opening; and in a direction perpendicular to a plane where the substrate is located, an outer sidewall of the annular pattern surrounds the corresponding first opening, and an inner sidewall of the annular pattern is located in the corresponding first opening. A light-emitting device is located in an inner sidewall of one of the annular patterns.