Backlight Module Overlapped Film Design for Joint Mark Reduction
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Solution Overview
Problem
Conventional direct type backlight modules experience bright/dark joint marks due to overlapped reflectors, leading to poor display quality when multiple reflectors are joined, as the overlapped areas result in light loss and uneven optical behavior.
Innovation Solution
A backlight module design featuring an optical control layer with a first and second optical film, where the first film has inner openings and the second film has corresponding outer openings, allowing light to emit through the overlapped area, and the opening edge of the second film is positioned around the first film's openings, reducing light loss and joint marks by improving transmittance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple reflectors are jointed to create large size modules, then the module size can be increased, but bright/dark joint marks occur in the overlapped area leading to poor display quality
Solution Approach 1:
The patent applies local quality by creating a stepped structure where the first optical film has a first step and the second optical film has a second step, with the first step positioned higher than the second step. This localized structural differentiation in the overlapped area controls light reflection and emission paths, ensuring uniform light distribution and eliminating bright/dark joint marks while maintaining large module size capability
Solution Approach 2:
The patent transitions from a two-dimensional planar reflector structure to a three-dimensional stepped structure by introducing height differences between the first and second steps. This dimensional change allows precise control over light emission angles and paths through the different step levels, resolving the joint mark issue while maintaining scalability to large module sizes
2Ease of manufacture
If double-sided tape is used to adhesive reflectors, then the reflectors can be joined, but the overlapped area still produces bright/dark joint marks
Solution Approach 1:
The stepped structure with different height levels creates localized optical paths that control light emission from the overlapped area. The first step and second step are positioned at different heights to specificallY address the joint mark problem in the overlapped region, while the adhesive method maintains ease of manufacture
3Manufacturing precision
If the overlapped area of optical films is reduced, then joint marks may be minimized, but light loss increases due to increased thickness
Solution Approach 1:
By introducing the vertical dimension with stepped structures at different heights, the patent creates differentiated light emission paths. The first step and second step emit light at different angles and positions, which compensates for the increased thickness effect and prevents light loss while maintaining joint mark reduction
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 enhances light emission through the overlapped area, reducing light loss and bright/dark joint marks, thereby improving display quality.
Implementation Method 1
The optical control layer disposed on the light source module is configured to distribute light generated from the light source to emit through different positions
Implementation Method 2
The first optical film comprises a plurality of first light exit openings; wherein the first optical film has a first overlap area on a first side, the first overlap area has at least one first inner opening
Data Source
AI summary
The present invention provides a backlight module, comprising a light source module and an optical control layer disposed on the light source module. The optical control layer comprises a first optical film and a second optical film. The first optical film has a first overlap area on a first side, the first overlap area comprises first inner openings; the second optical film comprises a second overlap area near the first overlap area. The second overlap area matches the first overlap area. The second overlap area comprises second outer openings corresponding to the first inner openings.