Backlight Plate Reflective Layer Undercut Prevention
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Solution Overview
Problem
The reflectance of backlight plates in existing mini-LED display technology is low due to frequent undercut of the reflective layer, which affects the display brightness.
Innovation Solution
A production method for a backlight plate involving a light-transmitting substrate with distinct areas, where a pad is formed and a photosensitive material is coated to create a reflective layer, with controlled exposure and development to prevent undercut and enhance bonding between photosensitive molecules, thereby increasing reflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a reflective layer is used on the surface of a backing plate to increase display brightness, then the display brightness is improved, but the reflective layer is prone to undercut resulting in lower reflectance
Solution Approach 1:
The backing plate is divided into a light-transmitting area and a light-shielding area, with the reflective layer selectively formed only on the light-shielding area. This segmentation prevents undercut at the edges of the reflective layer by creating a clear boundary between where the reflective layer exists and where it does not, thereby maintaining reflectance while enabling brightness improvement
Solution Approach 2:
The reflective layer is applied locally only to the light-shielding area rather than uniformly across the entire backing plate surface. This local quality approach ensures the reflective layer has proper adhesion and structural integrity where it is needed, preventing undercut while maintaining high reflectance in the designated area
2Strength
If exposure intensity is increased to improve reflective layer formation, then bonding between photosensitive molecules is enhanced, but manufacturing precision may be compromised
Solution Approach 1:
The exposure process uses exposure intensity within a specific range (300-800 mJ) that is sufficient to achieve adequate bonding between photosensitive molecules without being excessive. This partial action approach ensures proper curing of the reflective layer while avoiding over-exposure that would compromise manufacturing precision and cause defects
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 method ensures the stability and reflectance of the reflective layer, improving the overall brightness of the backlight plate by increasing photo sensibility and bonding between photosensitive molecules, preventing undercut and enhancing the display's luminous effect.
Implementation Method 1
exposing a position of the second area at opposite sides of the light-transmitting substrate that the reflective layer corresponds to... increasing photo sensibility and bonding between photosensitive molecules
Data Source
AI summary
A production method of a backlight plate, a backlight plate and a backlight module are provided. The method includes providing a light-transmitting substrate which comprises a first area and a second area, forming a pad on the light-transmitting underlay substrate corresponding to the first area, coating a layer of photosensitive material on the light-transmitting substrate and the pad to form a reflective layer, exposing a position of the second area at opposite sides of the light-transmitting substrate that the reflective layer corresponds to, and developing the reflective layer to form a groove for exposing the pad on the first area that the reflective layer corresponds to. The present disclosure ensures the stability of the reflective layer and enhances the overall reflectance of the backlight plate.