Black Edge Prism Sheet for Backlight Module Light Leakage
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Solution Overview
Problem
The current method of attaching a rectangular frame-shaped black shading tape to the periphery of prism sheets for display devices is time-consuming, costly, and increases the thickness of the backlight module, leading to inefficiencies and material waste.
Innovation Solution
A black edge prism sheet is manufactured with a substrate and a shadowless glue film layer featuring sawtooth or bump particle structures, eliminating the need for shading tape by integrating a black shading surface directly onto the prism sheet through a process involving coating, molding, and ultraviolet curing, followed by ink printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rectangular frame-shaped black shading tape is attached to the periphery of the prism sheet, then light leakage is prevented, but production time increases and production rate decreases
Solution Approach 1:
The patent merges the shading function with the prism sheet itself by printing the black shading layer directly onto the periphery of the prism sheet during the manufacturing process. This integration eliminates the need for separate shading tape attachment, thereby preventing light leakage while maintaining high production rates.
Solution Approach 2:
The shading layer is printed onto the prism sheet during the manufacturing process itself, before the prism sheet is installed in the display device. This preliminary action eliminates the need for subsequent attachment steps, improving production efficiency while ensuring light leakage prevention.
2Reliability
If a rectangular frame-shaped black shading tape is attached to the periphery of the prism sheet, then light leakage is prevented, but material waste increases and cost increases
Solution Approach 1:
The shading function is merged into the prism sheet structure itself through direct printing during manufacturing. This eliminates the need for separate shading tape materials and reduces material waste associated with attaching and potentially scrapping mismatched components.
Solution Approach 2:
The patent changes the approach from using a separate physical tape material to applying a printed shading layer. This parameter change in material form (from tape to printed layer) reduces material waste and manufacturing cost while maintaining the light leakage prevention function.
3Reliability
If a rectangular frame-shaped black shading tape is attached to the periphery of the prism sheet, then light leakage is prevented, but the thickness of the backlight module increases
Solution Approach 1:
The shading layer is merged with the prism sheet as an integrated component rather than a separate attached layer. This integration eliminates the additional thickness that would be introduced by attaching a separate shading tape, thereby maintaining thin module profiles while preventing light leakage.
Solution Approach 2:
The patent uses a thin printed shading layer instead of a bulky shading tape. This thin film approach maintains the light leakage prevention function while minimizing the increase in module thickness, aligning with the trend toward thinner display devices.
4Reliability
If shading tape with a hollow center is used, then the periphery is shaded, but material waste increases and cost increases
Solution Approach 1:
The shading function is merged with the prism sheet manufacturing process through direct printing. This eliminates the need for separate hollow-center shading tape materials, reducing material waste and cost while achieving the same peripheral shading effect.
Solution Approach 2:
The patent uses a printed shading layer that can be applied directly during manufacturing without requiring durable, expensive hollow-center shading tapes. This approach uses simpler, more cost-effective materials while achieving the required shading function.
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
This approach enhances production efficiency, reduces production costs, and minimizes the thickness of the backlight module by integrating a black shading surface without the need for additional tape, while ensuring effective light control and reduced material waste.
Implementation Method 1
a central region, the central region has multiple first geometry structures arranged in parallel to each other; and a peripheral region, the peripheral region has multiple second geometry structures arranged adjacent to each other
Implementation Method 2
S3: irradiating the shadowless glue film layer with an ultraviolet lamp to cure the shadowless glue film layer
Data Source
AI summary
A black edge prism sheet is disclosed, having a substrate and a shadowless glue film layer molded on one side of the substrate. The shadowless glue film layer includes: a central region having multiple first geometry structures arranged in parallel to each other, forming a surface of prisms, and a peripheral region. The peripheral region has multiple second geometry structures arranged adjacent to each other. The peripheral region is located outside the central region and extends to edge of the shadowless glue film layer. An ink layer is printed on the multiple second geometry structures.