Co-Extruded Light-Guide and Reflective Layer for Uniform Backlight
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional backlight assemblies for display devices suffer from light loss, increased production costs, line defects, and manufacturing difficulties due to air spacing between the light-guide plate and reflection plate, as well as non-uniform brightness distribution caused by glazing bands.
Innovation Solution
A uniform reflective light-guide apparatus is developed, integrating a light-guiding layer and a reflective layer manufactured by a co-extrusion process, eliminating air spacing and incorporating diffusing particles, reflective particles, and a coarse surface to enhance light distribution and reflection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a reflection plate is added to increase light reflection, then light reflection efficiency is improved, but light loss increases due to air spacing between plates
Solution Approach 1:
The patent combines the reflection plate and light-guide plate into a single integrated structure where the reflective layer is directly formed on the back surface of the light-guide plate. This eliminates the air spacing between separate plates, reducing light loss from Fresnel reflection at interfaces while maintaining the light reflection function. The integrated design also simplifies the overall structure by removing the need for separate reflection plates and their mounting mechanisms.
Solution Approach 2:
The patent uses a composite structure with a light-guide plate made of transparent material and a reflective layer applied to its back surface. This composite design allows the front surface to transmit light effectively while the back surface reflects stray light back into the light-guide plate, optimizing both light transmission and reflection functions within a single integrated component.
2Manufacturing precision
If screen printing process is used to create micro-structures on light-guide plate, then light distribution is improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent replaces the mechanical screen printing process with a chemical etching method to create micro-structures on the light-guide plate. The chemical etching process uses corrosive solutions to selectively remove material and form the desired micro-patterns, eliminating the need for screen preparation, inking, and printing operations. This substitution simplifies the manufacturing process, reduces production costs, and improves manufacturing precision by achieving more uniform micro-structures.
3Illumination intensity
If diffusing membrane is added to homogenize lights, then brightness uniformity is improved, but production cost increases
Solution Approach 1:
The patent integrates the light-diffusing function directly into the light-guide plate by forming micro-structures on its surface. These micro-structures scatter and homogenize the light as it passes through the plate, eliminating the need for a separate diffusing membrane. This integration maintains brightness uniformity while reducing the total number of components and simplifying the overall structure.
4Illumination intensity
If lens module is added to enhance luminosity, then light coverage is improved, but manufacturing difficulty and cost increase
Solution Approach 1:
The patent integrates the light-focusing and distributing functions directly into the light-guide plate through strategically designed micro-structures on its surface. These micro-structures act as miniature optical elements that focus and distribute light without requiring a separate lens module. This integration maintains enhanced luminosity and light coverage while eliminating the manufacturing complexities associated with lens modules.
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 significantly reduces light loss, lowers production costs, minimizes line defects, and achieves uniform brightness distribution, improving the overall efficiency and luminance of the backlight module.
Implementation Method 1
The reflective layer can reflect the incident lights back to the light-guiding layer
Implementation Method 2
Theoretically, the light-guide plate is to direct the incident lights to a particular side (usually the front surface) of the plate
Implementation Method 3
incorporating diffusing particles, reflective particles, and a coarse surface to enhance light distribution and reflection efficiency
Data Source
AI summary
A uniform reflective light-guide apparatus can accompany an optional edge light source and includes a light-guiding layer, a reflective layer and a light-exiting surface. The light-guiding layer further has a lateral side to define a light-introducing surface for allowing entrance of lights from the edge light source. The reflective layer is to reflect incident lights back to the light-guiding layer. The light-exiting surface perpendicular to the light-introducing surface is to allow at least a portion of the lights in the light-guiding layer to leave the light-guide apparatus. The reflective layer and the light-guiding layer are manufactured integrally by a co-extrusion process so as to avoid possible existence of an air spacing between the reflective layer and the light-guiding layer.