Mini-LED Backlight Module Metal Laminating Layer Design
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Solution Overview
Problem
Indium tin oxide (ITO) in traditional mini-LED backlight modules exhibits low conductivity and connection failure due to aging at high temperatures, leading to slow response times and increased light loss and energy consumption.
Innovation Solution
A backlight module design featuring a metal laminating layer composed of multiple layers of molybdenum, copper, and metal oxide, which contacts exposed portions of the first and second metal layers through via holes, enhancing conductivity and adhesion, and utilizing a second metal with high light reflectance to replace organic reflective layers, thereby improving connection reliability and reducing manufacturing steps and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ITO layer is used as reflective material in traditional mini-LED backlight modules, then light reflectance is achieved, but conductivity is low and connection function is lost due to aging at high temperature
Solution Approach 1:
The patent applies composite materials by combining multiple metal layers (first metal layer with high conductivity, second metal layer with high light reflectance) to create a metal laminating layer that simultaneously achieves both high conductivity and high light reflectance, replacing the single-material ITO layer that could not satisfy both requirements
Solution Approach 2:
The patent changes the material parameters by selecting specific metals with complementary properties: the first metal layer uses materials with high conductivity (such as aluminum or copper), while the second metal layer uses materials with high light reflectance (such as silver or aluminum), thereby optimizing both electrical and optical parameters
2Reliability
If ITO material is used for via holes, then manufacturing is simplified, but response time is slow and connection function is lost after high temperature aging
Solution Approach 1:
The patent uses composite materials in the metal laminating layer where the first metal layer provides high conductivity for fast response time, while the overall composite structure ensures connection reliability under high temperature conditions, overcoming the limitations of single-material ITO
3Reliability
If multiple separate layers (organic reflective layer and ITO layer) are used, then light reflection and conductivity are addressed, but manufacturing complexity and costs increase
Solution Approach 1:
The patent merges the functions of the organic reflective layer and the ITO layer into a single integrated metal laminating layer structure, where the first metal layer provides conductivity and the second metal layer provides light reflectance, thereby simplifying manufacturing processes and reducing costs while maintaining both electrical and optical functions
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 metal laminating layer ensures high conductivity and adhesion between metal layers, addresses ITO's conductivity issues, and achieves high light reflectivity, reducing manufacturing complexity and costs by integrating organic and ITO layers into a single reflective layer.
Implementation Method 1
the light reflectance of the second metal is greater than or equal to 80%
Data Source
AI summary
A backlight module includes an array substrate and light-emitting devices disposed on the array substrate. The array substrate includes: a substrate, a first metal layer and a second metal layer disposed on the substrate; a planarization layer covering the first metal layer and the second metal layer and exposing portions of the first metal layer and the second metal layer; and a metal laminating layer disposed on the planarization layer and contacting the portions of the first metal layer and the second metal layer exposed by the planarization layer; the metal laminating layer including at least one first metal layer, at least one second metal layer, and at least one metal oxide layer, and the first metal is molybdenum. The second metal has high light reflectivity and its conductivity is higher than that of the metal oxide, which can effectively reduce optical loss and achieve higher conductivity.