Backlight Module Optical Substrate Trenches
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Solution Overview
Problem
Conventional backlight modules for large-scale flat panel displays face challenges such as increased thickness, complex manufacturing processes, high cost, and low luminous efficiency due to the use of fiber-based systems, which result in poor light utilization and energy loss.
Innovation Solution
A backlight module design incorporating an optical substrate with accommodation trenches for light guide pipes, featuring micro-optics structures and reflectors to enhance light coupling and distribution, utilizing translucent materials like PMMA, glass, or PVC, and optimizing geometric configurations to improve light-guiding efficiency and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If fiber-based systems are used for light guiding in large-scale flat panel displays, then light distribution can be achieved, but the module thickness increases and manufacturing complexity increases
Solution Approach 1:
The light guiding function is segmented into multiple independent light guide plates arranged in parallel, each guided by its own light guide pipe. This segmentation allows each component to be thinner while collectively achieving the required light distribution across the large display panel, thereby reducing overall module thickness compared to a single thick light guide plate approach.
Solution Approach 2:
Light guide pipes serve as intermediary elements that couple light sources to light guide plates, and optical adhesives act as intermediaries to couple light guide plates to the display panel. These intermediary components enable efficient light transfer while maintaining a compact, thin structure, avoiding the need for thick fiber-based light guiding systems.
2Illumination intensity
If fiber-based systems are used for light guiding, then light transfer is achieved, but manufacturing process becomes complicated and cost increases
Solution Approach 1:
The complex mechanical fiber-based light guiding system is replaced with an optical adhesive-based system. Optical adhesives provide both optical coupling and mechanical bonding functions, simplifying the manufacturing process. The light guide pipes and light guide plates can be directly bonded to the display panel using optical adhesives, eliminating the need for complex fiber assembly and alignment procedures.
Solution Approach 2:
The system transitions from using rigid fiber-based light guiding structures to flexible optical adhesive-based coupling. This parameter change in the coupling mechanism allows for easier manufacturing and assembly, reducing production complexity and cost while maintaining light transfer efficiency through optimized optical adhesive layers and light guide plate geometries.
3Area of stationary object
If light guide plate thickness is increased for large-scale displays, then light distribution coverage is improved, but module volume increases
Solution Approach 1:
Instead of increasing light guide plate thickness in the vertical dimension to achieve better light distribution coverage, the system uses multiple light guide plates arranged in parallel layers. This dimensional approach allows the light distribution coverage to be achieved through lateral arrangement and optical coupling rather than increasing individual plate thickness, thereby controlling module volume.
Solution Approach 2:
Multiple light guide plates are nested or arranged in close proximity within the module structure, with optical adhesives providing compact coupling between them and to the display panel. This nested arrangement achieves extensive light distribution coverage across the large display area while maintaining a compact overall module volume by efficiently utilizing the available space through layered configuration.
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 enables a thinner, more efficient large-scale backlight module with improved luminous efficiency and simplified manufacturing, reducing costs and complexity while maintaining uniform light distribution.
Implementation Method 1
the at least one first light is transferred in the at least one light guide pipe and leaves the at least one light guide pipe when being reflected by the optical substrate
Implementation Method 2
leaves the at least one light guide pipe when being reflected by the optical substrate
Data Source
AI summary
A backlight module may include an optical substrate, at least one light guide pipe, and at least one first light source. At least one accommodation trench is disposed on the optical substrate for accommodating the light guide pipe. The first light source is disposed at one side of the light guide pipe and is arranged for emitting at least one first light into the light guide pipe. The first light is transferred in the light guide pipe and leaves the light guide pipe when being reflected by the optical substrate.