Backlight Unit Integrating Light Diffusion Layer with LED Package
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing backlight units face challenges in simplifying the assembly process, reducing manufacturing time, and minimizing image quality degradation due to misalignment of light source modules and lenses, while also resulting in increased thickness with thicker lenses.
Innovation Solution
A backlight unit design featuring light emitting units with an integrally formed light diffusion layer on the LED package, which is mounted within a reflector unit, simplifying assembly and reducing thickness by diffusing light and reflecting it from the reflector, thus eliminating the need for a separate lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a separate lens is mounted between the light source module and the reflector, then light distribution can be improved, but the assembly process becomes complex and manufacturing time increases
Solution Approach 1:
The patent combines the lens function with the light source module by integrating a light diffusing layer directly onto the substrate holding the LED packages. This merging eliminates the need for a separate lens component, simplifying the assembly process while maintaining light distribution functionality. The light diffusing layer is formed as part of the substrate structure, creating a unified component that performs both structural support and optical diffusion functions.
2Illumination intensity
If a separate lens is mounted between the light source module and the reflector, then light distribution can be improved, but manufacturing time increases
Solution Approach 1:
The lens function is merged with the light source module substrate, eliminating separate lens assembly steps. The light diffusing layer is integrated during substrate fabrication, reducing manufacturing工序 and time. This consolidation allows the light source module to be produced as a single integrated unit, improving production efficiency.
3Illumination intensity
If the lens is made thicker to improve light distribution, then illumination quality improves, but the overall thickness of the backlight unit increases
Solution Approach 1:
Instead of using a thick lens throughout, the patent applies a light diffusing layer with varying local properties. The diffusion characteristics are optimized locally at the substrate level, allowing effective light distribution without requiring significant thickness. The light diffusing layer provides targeted optical functionality exactly where needed, maintaining thin overall profile.
4Ease of manufacture
If the light source module and lens are mounted separately, then manufacturing flexibility is improved, but alignment precision deteriorates
Solution Approach 1:
The light source module and lens function are merged into a single integrated structure. The light diffusing layer is formed directly on the substrate that holds the LED packages, ensuring perfect alignment between the light sources and the diffusion function. This integration eliminates alignment issues while maintaining manufacturing flexibility, as the entire assembly is produced as one unit.
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
This design simplifies the assembly process, reduces manufacturing time, and achieves a slim, compact backlight unit with improved image quality by integrating the light diffusion layer with the LED package, enhancing light distribution and reflection.
Implementation Method 1
a light diffusion layer formed on an opposite surface of the substrate in the LED package
Implementation Method 2
a reflector having a reflector unit formed to have a space to receive each of the plurality of light emitting units
Data Source
AI summary
The present embodiment comprises: a plurality of light-emitting units; and a reflector including reflector units having spaces formed to receive the plurality of light-emitting units, respectively. Each of the plurality of light-emitting units includes an LED package mounted on a substrate and a light diffusion layer having a groove portion formed on a surface opposite to the substrate in the LED package, wherein the outer circumference of the light diffusion layer faces the inner surface of a reflector unit. In the reflector, the plurality of reflector units are integrally formed, the spaces expand along a direction extending away from the substrate, and a wall forming each of the spaces surrounds the outer circumference of each of the LED package and the light diffusion layer.