Backlight Module Dual Optical Sheets Thickness Reduction
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Solution Overview
Problem
Conventional backlight modules face challenges in reducing production costs without increasing thickness, particularly due to the high cost of brightness enhancement films (BEF) which are often replaced with thicker prism plates, leading to increased module thickness.
Innovation Solution
A backlight module design featuring two optical sheets with a first optical sheet and a second optical sheet having holes for needles, which maintains compact thickness by using microstructures and a conical stem-needle coupling, allowing for light diffusion and convergence without additional thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a prism plate is used to replace the brightness enhancement film to reduce cost, then the production cost is reduced, but the total thickness of the backlight module increases
Solution Approach 1:
The patent divides the optical function into two separate optical sheets: a first optical sheet with microstructures for light convergence and a second optical sheet for light diffusion. This segmentation allows each sheet to be optimized independently for thinness while maintaining their respective functions, avoiding the need for a thick single-layer prism plate.
Solution Approach 2:
The two optical sheets are nested within the existing backlight module structure, with the first optical sheet positioned above the second optical sheet. Both sheets are integrated into the space between the case and the liquid crystal panel without requiring additional thickness, effectively nesting the optical functions within the existing form factor.
2Illumination intensity
If a single thick prism plate is used to provide light convergence, then the light converging function is achieved, but the total thickness of the backlight module increases
Solution Approach 1:
The light convergence function is separated from the light diffusion function into two distinct optical sheets. The first optical sheet with microstructures handles light convergence to enhance luminosity, while the second optical sheet handles diffusion. This segmentation allows each component to be made thin while collectively achieving the desired optical performance without increasing total thickness.
Solution Approach 2:
The first optical sheet is designed with specific local properties (microstructures for convergence) only where needed to enhance luminosity within the visual angle, while the second optical sheet provides diffusion. This localized optimization allows thin design while achieving specific optical goals.
3Illumination intensity
If multiple optical components are added to improve light distribution, then the light diffusion and convergence functions are enhanced, but the total thickness of the backlight module increases
Solution Approach 1:
The patent merges the light diffusion function and light convergence function into a single integrated optical system consisting of two thin optical sheets working together. This merging allows multiple optical functions to be achieved within the thickness of a single optical component layer, avoiding the need to stack multiple thick components.
Solution Approach 2:
The patent transitions from a single-layer thick optical component to a multi-layer thin optical sheet structure. By organizing optical functions across multiple thin layers (first optical sheet for convergence, second optical sheet for diffusion) rather than within a single thick layer, the solution achieves enhanced light distribution without increasing total thickness.
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 design effectively reduces the total thickness of the backlight module while enhancing light distribution and reducing costs by eliminating the need for additional diffusion films and maintaining structural integrity through a compact and secure optical sheet arrangement.
Implementation Method 1
The BEF 144 has a thickness about 0.062 mm to 0.375 mm and a plurality of prism structures 144a formed at an upper side thereof to converge light. Thus, the exit angle of the light emitting from the BEF 144 becomes smaller. Therefore, the luminosity within the visual angle of the backlight module 100 is enhanced.
Implementation Method 2
The diffusion plate 130 mainly diffuses the light generated by the CCFL 120 so that the light can be projected more evenly to the liquid crystal panel (not shown in the drawing) without creating uneven luminosity on the display of the LCD.
Implementation Method 3
The CCFL 120 is located in the case 110 which has a reflective sheet (not shown in the drawing) on the inside surface to use light generated by the CCFL 120 more effectively.
Data Source
AI summary
A backlight includes a case, pluralities of light sources, pluralities of needles, pluralities of supporting portions, a first optical sheet, a second optical sheet, and pluralities of first microstructures. The light sources are disposed inside the case, the needles are disposed on the bottom surface of the case, and the supporting portions are disposed on the needles. The first optical sheet is supported on the top of the needles. The second optical sheet placed under the first optical sheet has pluralities of holes, and the needles penetrate the holes. The second optical sheet is supported on the supporting portions. The first microstructures are disposed on the first optical sheet or on the second optical sheet to provide a light condensing function.