Backlight Source Substrate Segmentation for Warpage Yield
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Solution Overview
Problem
In direct type backlight assemblies, the warpage of flexible printed circuits (FPC) or printed circuit boards (PCB) leads to reduced yield as light emitting elements at warped positions cannot emit light, affecting the performance of TFT-LCD displays.
Innovation Solution
A backlight source with a base substrate divided into light emitting regions, each equipped with light emitting elements, first and second common polar lines, and wires, allowing independent brightness adjustment through a driving circuit, reducing the likelihood of warpage and improving yield by using a harder substrate and specific wiring configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If FPC or PCB is used to arrange light emitting elements, then the backlight assembly can be manufactured with standard circuit board technologies, but the FPC or PCB warpage causes light emitting elements at warped positions to fail, reducing yield
Solution Approach 1:
The base substrate is divided into multiple light emitting regions, with each region independently controllable. This segmentation allows the system to tolerate failures in individual regions while maintaining overall functionality, thereby improving yield despite potential warpage issues.
Solution Approach 2:
The patent changes the physical parameter of the substrate from flexible (FPC) or rigid (PCB) to a harder base substrate that is less prone to warpage. This parameter change directly addresses the warpage problem while maintaining manufacturability through standard substrate processing techniques.
2Strength
If FPC or PCB is used to arrange light emitting elements, then the circuit board can provide structural support and electrical connection, but the warpage leads to contact failures between light emitting elements and the driving circuit
Solution Approach 1:
The patent changes the mechanical parameter of the substrate by using a harder base substrate instead of flexible FPC. This parameter change provides sufficient structural support while minimizing warpage-induced contact failures, thereby improving both strength and contact reliability.
3Illumination intensity
If the base substrate is divided into multiple light emitting regions with independent brightness control, then the dynamic range and image quality are enhanced, but the wiring configuration and driving circuit complexity increase
Solution Approach 1:
The patent merges multiple light emitting elements within each light emitting region to share common polar lines and wiring structures. This merging reduces the overall wiring complexity while maintaining independent brightness control of each region, thereby achieving brightness control without excessive device complexity.
4Use of energy by moving object
If multiple light emitting regions are controlled independently, then the dynamic range is increased and power consumption is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges common polar lines and wiring structures across multiple light emitting regions, reducing the number of independent manufacturing steps. This merging approach enables independent brightness control for power savings while keeping the manufacturing process complexity manageable through standardized fabrication techniques.
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 independent brightness control of light emitting regions, enhances image quality by increasing dynamic range, reduces power consumption, and minimizes the risk of contact failures between light emitting elements and the driving circuit, thereby improving the overall performance and yield of the backlight source.
Implementation Method 1
at least one of the plurality of light emitting regions comprises a plurality of light emitting elements
Data Source
AI summary
A backlight source and a manufacture method thereof, a display device are provided. The backlight source includes a base substrate, the base substrate is divided into a plurality of light emitting regions, and at least one of the plurality of light emitting regions comprises a plurality of light emitting elements, a first common polar line, and a second common polar line. Light emitting brightness of at least one of the light emitting regions is adjustable independently.