Backlight Module Blue LEDs Color Conversion Cost Reduction

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Solution Overview

Problem

Current backlight modules using local dimming techniques face challenges in reducing manufacturing costs while maintaining brightness and visual quality, as decreasing the number of light emitting diodes can lead to insufficient brightness and hot spots, and power dissipation issues.

Innovation Solution

A backlight module design featuring a substrate with blue light emitting diodes, a protection layer, and a color conversion element, along with a reflective layer and optical films with microstructure arrays, which reduces the number of light emitting diodes required, enhances light efficiency, and improves visual effects by optimizing light distribution and utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the number of light emitting diodes is decreased to reduce manufacturing cost, then manufacturing cost is reduced, but brightness becomes insufficient

Engineering Contradiction:

Improvemanufacturing costVSAvoidbrightness

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

The patent changes the spectral parameters of the light source by using blue light emitting diodes combined with yellow phosphors to generate white light. This parameter change allows fewer LEDs to be used while maintaining adequate brightness, as the converted white light has better luminous efficiency compared to traditional white LEDs.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite light source system combining blue light emitting diodes with yellow phosphor materials. This composite approach creates an efficient white light generation system that improves luminous output per LED, thereby reducing the total number of LEDs needed while maintaining brightness requirements.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If the number of light emitting diodes is decreased to reduce manufacturing cost, then manufacturing cost is reduced, but hot spots occur

Engineering Contradiction:

Improvemanufacturing costVSAvoidhot spots

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent changes the light emission parameters by using blue LEDs with phosphor conversion instead of traditional white LEDs. This parameter change results in a more uniform spectral distribution that reduces hot spot formation while allowing fewer LEDs to be used, thereby reducing manufacturing cost.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the number of light emitting diodes is decreased to reduce manufacturing cost, then manufacturing cost is reduced, but power dissipation occurs

Engineering Contradiction:

Improvemanufacturing costVSAvoidpower dissipation

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent changes the operational parameters of the light source system by using blue light emitting diodes with phosphor conversion. This parameter change improves the overall energy conversion efficiency, reducing power dissipation while allowing a reduction in the number of LEDs needed, thereby achieving both cost reduction and energy efficiency improvement.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite light generation system using blue LEDs and yellow phosphors. This composite approach achieves higher luminous efficiency with fewer components, reducing both manufacturing cost and power dissipation simultaneously.

Inventive Principle:

Principle #40Composite materials

4Manufacturing precision

If local dimming technique is applied to achieve high dynamic range, then display quality is improved, but manufacturing cost increases

Engineering Contradiction:

Improvedisplay qualityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental light source parameters to blue LEDs with phosphor conversion, which provides inherent advantages in luminous efficiency and uniformity. This parameter change enables improved display quality through better light control characteristics while reducing the complexity and cost of implementing local dimming techniques.

Inventive Principle:

Principle #35Parameter changes

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 solution achieves a significant reduction in manufacturing costs, improves light efficiency by up to 50%, and decreases power consumption while maintaining or enhancing brightness and visual quality, allowing for a more efficient and cost-effective display device.

Implementation Method 1

a plurality of light emitting diodes disposed on the substrate, wherein the plurality of light emitting diodes are blue light emitting diodes

Methodology Applied

Scientific EffectLight emitting diode: Light Emitting Diode

Implementation Method 2

a color conversion element, disposed on the plurality of light emitting diodes

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Data Source

PatentUS11482182B2Electronic device

Publication Date: 2022.10.25 INNOLUX CORP

AI summary

An electronic device including a backlight module is disclosed. The backlight module includes: a substrate; a plurality of light emitting diodes disposed on the substrate, wherein the plurality of light emitting diodes are blue light emitting diodes; a protection layer disposed on the substrate and covering the plurality of light emitting diodes; and a color conversion element, disposed on the plurality of light emitting diodes.