Composite Diffuser Plate Curved Protrusions for TV Thickness
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Solution Overview
Problem
Direct-light TVs face challenges in achieving thinness and market competitiveness due to issues with LED Mura and uneven brightness caused by limited LED density and optical distance constraints, which increase costs and hinder market penetration.
Innovation Solution
A composite diffuser plate with a light-emitting layer, a middle layer with curved protrusions, and a light-entering layer, where refractive indexes are gradually increased, enhancing light divergence and allowing for a larger light-emitting area with a smaller optical distance, thereby reducing LED Mura and enabling a slimmer TV design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the optical distance between the diffuser plate and LED is reduced to achieve thinner TV design, then the TV thickness is reduced, but LED Mura and uneven brightness appear
Solution Approach 1:
The patent applies curved protrusions on the light-entering surface of the diffuser plate to replace the conventional flat surface. These curved structures refract and scatter LED light more effectively, improving light diffusion uniformity. This allows the optical distance to be reduced while maintaining brightness uniformity, thereby resolving the contradiction between thinness and brightness uniformity.
Solution Approach 2:
The patent modifies the refractive index distribution by using multiple layers with different refractive indexes (light-entering layer, middle layer, light-emitting layer). This gradual change in refractive parameters enhances light control and diffusion, enabling reduced optical distance without sacrificing brightness uniformity.
2Reliability
If LED density is increased to improve brightness uniformity and reduce LED Mura, then the cost increases and the design becomes more complex
Solution Approach 1:
The patent extracts the light diffusion function from the LED arrangement and transfers it to the diffuser plate structure. By incorporating curved protrusions and multi-layer refractive index design into the diffuser plate, the system achieves brightness uniformity without relying on high LED density, thus reducing design complexity and cost.
3Ease of manufacture
If the pitch between LEDs is increased to reduce cost, then LED density decreases, but LED Mura and uneven brightness become more apparent
Solution Approach 1:
The patent changes the optical parameters by implementing a multi-layer structure with gradually increasing refractive indexes and curved surface geometries. This enhances light scattering and diffusion efficiency, allowing larger LED pitch while maintaining brightness uniformity, thus resolving the contradiction between manufacturing cost and brightness uniformity.
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 increases the light-emitting area and reduces LED Mura, enabling a more competitive and cost-effective ultra-thin direct-light TV design by allowing for a larger pitch between LEDs and a thinner backlight module.
Implementation Method 1
refractive indexes of the light-emitting layer, the middle layer and the light-entering layer are gradually increased
Implementation Method 2
at least one surface of the middle layer is provided with an array of curved protrusions
Data Source
AI summary
This invention provides a composite diffuser plate comprising a light-emitting layer for emitting light, a middle layer for guiding light, and a light-entering layer for entering light, being sequentially stacked downwardly. At least one surface of the middle layer is provided with an array of curved protrusions. Refractive indexes of the light-emitting layer, the middle layer and the light-entering layer are gradually increased. This invention further provides an ultra-thin direct type backlight module. In the composite diffuser plate of this invention, in addition to a gradual increase in refractive indexes of the light-emitting layer, the middle layer and the light-entering layer, the middle layer is provided with a microstructure having curved protrusions, which further enhances diverging effect of emitting angle. The direct-light TV can increase a light-emitting area with a small OD value, and thus improves a LED Mura problem, realizing a slim direct-light TV and enhancing market competitiveness.