Backlight Module Optical Film Microstructures Concealing Defects
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Solution Overview
Problem
Backlight modules with high light collecting efficiency face challenges in concealing small defects, leading to decreased assembly yield rates due to poor concealing ability, which hinders slim design and manufacturing efficiency.
Innovation Solution
A backlight module design incorporating a light guide plate, optical film with microstructures and a diffusion layer, and prism sheets to enhance light emission efficiency and concealing ability, increasing the assembly yield rate by optimizing the orientation and structure of optical microstructures and diffusion particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a reverse prism sheet is used to replace two laminated brightness enhancement films to increase light collecting efficiency and reduce thickness, then the light collecting efficiency is improved and the module thickness is reduced, but the concealing ability to prevent small defects deteriorates
Solution Approach 1:
The optical film is segmented into multiple functional layers: a first prism sheet for light collection, an optical film with microstructures and diffusion layer for both light distribution and defect concealment, and a second prism sheet for additional light guidance. This segmentation allows each layer to perform its specific function optimally while working together to resolve the contradiction between light collecting efficiency and concealing ability.
Solution Approach 2:
The optical film uses a composite structure combining transparent resin material with optical microstructures and a diffusion structure layer. This composite design integrates the light-guiding properties of the microstructures with the light-diffusing properties of the diffusion layer, achieving both high light collecting efficiency and excellent concealing ability simultaneously.
2Illumination intensity
If two laminated brightness enhancement films are used to guide light to normal viewing angle, then the overall light intensity is improved, but the module thickness increases limiting slim design
Solution Approach 1:
The patent merges the functions of two separate brightness enhancement films into a single integrated optical film structure that combines prism sheets with an optical film containing microstructures and a diffusion layer. This consolidation maintains the light-guiding functionality while reducing the total number of layers and overall module thickness, enabling slim design without sacrificing light intensity.
3Length of stationary object
If the number of stacked optical film layers is decreased to achieve slim design, then the module thickness is reduced, but the concealing ability to prevent small defects deteriorates
Solution Approach 1:
The optical film incorporates a diffusion structure layer with specific local properties (diffusion coefficient and thickness) that provide enhanced concealing ability at the defect-prone interface region. This localized quality enhancement ensures that even with reduced overall layer count, the critical function of defect concealment is maintained through optimized local material properties.
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 improves light collecting efficiency and concealing ability, thereby increasing the assembly yield rate and allowing for a slim module design while reducing manufacturing costs.
Implementation Method 1
The optical microstructures are disposed on the light incident side of the substrate, and the extending direction of the optical microstructure intersects with the light incident surface of the light guide plate
Implementation Method 2
The first diffusion structure layer is disposed on the light emitting side of the substrate and overlaps the optical microstructures
Implementation Method 3
The first prism sheet and the second prism sheet are overlapped with the optical film, and each of them has a plurality of prism structures
Data Source
AI summary
A backlight module including a light guide plate, a light source, an optical film, a first prism sheet and a second prism sheet is provided. The light guide plate has a light incident surface and a light emitting surface. The light source is disposed on a side of the light incident surface. The optical film is overlapped with the light emitting surface and includes a substrate, a plurality of optical microstructures and a first diffusion structure layer. The optical microstructures are disposed on a light incident side of the substrate. An extending direction of the optical microstructures intersects with the light incident surface. The first diffusion structure layer is disposed on a light emitting side of the substrate and is overlapped with the optical microstructures. The first prism sheet and the second prism sheet are overlapped with the optical film and are positioned on the light emitting side.