Backlight Substrate Layout for Local Dimming and Fewer LED Cables
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Solution Overview
Problem
Current display devices face challenges in reducing substrate manufacturing costs, improving local dimming performance, minimizing reflective sheet lifting due to diodes, and reducing the number of cables connecting LED drivers to substrates, while also offering versatile substrate shapes and arrangements.
Innovation Solution
A display device design featuring a substrate with elongated bodies and legs, where light sources are arranged in rows along columns to form local dimming blocks, and a reflective sheet is bonded to the substrate with cut-lines corresponding to diodes to minimize lifting, reducing the complexity of cable connections between LED drivers and substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light sources are arranged in rows along columns to form local dimming blocks, then local dimming performance is improved, but device complexity increases
Solution Approach 1:
The light sources are divided into multiple rows and columns that form distinct local dimming blocks. Each block can be independently controlled to achieve local dimming effects, segmenting the backlight into controllable zones that improve image quality by reducing contrast loss in dark scenes.
Solution Approach 2:
Different regions of the substrate are assigned different functions: light sources are positioned at specific locations along rows and columns to create localized dimming zones. This local quality approach allows precise control over which areas are dimmed, enabling better image quality without uniformly affecting the entire display.
2Reliability
If a reflective sheet is bonded to the substrate with cut-lines corresponding to diodes, then reflective sheet lifting is minimized, but manufacturing complexity increases
Solution Approach 1:
The reflective sheet is divided into multiple segments with cut-lines that correspond to the diode positions on the substrate. This segmentation allows the reflective sheet to be separately manufactured and then precisely aligned with the diodes, reducing lifting issues while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
The reflective sheet is pre-cut into segments before being assembled to the substrate. This preliminary action of cutting the reflective sheet into manageable pieces allows for easier handling and precise positioning during assembly, reducing the risk of lifting while simplifying the overall manufacturing process through pre-prepared components.
3Device complexity
If the number of cables connecting LED driver and substrates is reduced, then device complexity is reduced, but connection reliability may worsen
Solution Approach 1:
Multiple cable connections are merged into a single integrated connection system. The substrate design consolidates the electrical connections between the LED driver and multiple light source rows/columns, reducing the total number of cables needed while maintaining all necessary electrical pathways through a unified connection architecture.
Solution Approach 2:
The reduced number of cables are designed to perform multiple functions simultaneously. Each cable is configured to carry multiple signals and power connections, making them multi-functional components that maintain connection reliability while reducing overall cable count and system complexity.
4Ease of manufacture
If substrate manufacturing costs are reduced, then ease of manufacture is improved, but manufacturing precision may worsen
Solution Approach 1:
The substrate is designed with segmented light source arrangements in rows and columns that can be manufactured using standardized processes. This segmentation allows for modular manufacturing where precision-critical elements are isolated to specific zones, enabling cost-effective production while maintaining necessary precision through repeated, standardized manufacturing steps.
Solution Approach 2:
The substrate design employs parameter optimization in the arrangement of light sources and diodes to achieve cost-effective manufacturing. By carefully selecting pitch, spacing, and positioning parameters, the design enables the use of lower-cost manufacturing processes while maintaining the precision required for local dimming performance through optimized geometric parameters.
Data Source
AI summary
A display device is provided. The display device of the present disclosure may include: a display panel; a frame positioned behind the display panel; a substrate positioned between the display panel and the frame, and coupled to the frame; and a plurality of light sources positioned on the substrate; wherein the substrate may include: an elongated body; and legs protruding from one long side of the body, and spaced apart from each other along the one long side, wherein the plurality of light sources may include: a first row of light sources positioned on the legs; and a second row of light sources positioned on the legs or the body, the second row being spaced apart from the first row, wherein the first and second rows of light sources are positioned along columns parallel to the legs, and are grouped into a local dimming block for at least each one of the columns.