Cup-Shaped Reflective Light Mixing Module for Uniform Illumination

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Solution Overview

Problem

Conventional Mini LED backlight modules suffer from uneven light distribution due to concentrated light emission, leading to dark areas between LED sources, which results in increased thickness and cost of the backlight module.

Innovation Solution

A light mixing module with a reflective structure that includes a main substrate, chip-level light emitting units, a diffusion plate, and a cup-shaped reflecting surface to redistribute light and compensate for dark areas, ensuring uniform brightness distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a conventional five-side LED light source is used, then the light emitting angle is limited to about 150°, but dark areas are generated between adjacent light sources resulting in uneven light distribution

Engineering Contradiction:

Improvelight distribution uniformityVSAvoidbacklight module structure

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

A reflective structure is introduced as an intermediary element between the LED light source and the display panel. This reflective structure redirects light that would otherwise create dark areas, effectively mediating the light distribution to achieve uniformity without increasing the number of LEDs or complexifying the overall module structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent modifies the light emission parameters by introducing a reflective structure with specific geometric parameters (reflection angles, surface areas) to change the light distribution pattern. This allows the existing LED light source to achieve better uniformity by altering how light is redirected rather than changing the LED characteristics themselves.

Inventive Principle:

Principle #35Parameter changes

2Illumination intensity

If the mixing distance is increased to improve light mixing, then the overall thickness of the backlight module increases, but the system becomes thicker and more expensive

Engineering Contradiction:

Improvelight mixing effectivenessVSAvoidbacklight module thickness

Core Design Contradiction:

Illumination intensityVSLength of moving object

Solution Approach 1:

Instead of increasing the mixing distance in the vertical dimension (which increases thickness), the patent introduces a reflective structure that operates in a different dimensional space - redirecting light laterally and utilizing previously wasted light paths. This achieves effective light mixing without extending the module thickness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent converts what would normally be wasted light (light that misses the display panel or creates dark areas) into a beneficial resource by using the reflective structure to redirect this light into useful illumination paths. This transforms the problem of light loss into a solution for improved light distribution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Illumination intensity

If more diaphragm layers are added to improve light mixing, then the thickness and cost of the backlight module increase

Engineering Contradiction:

Improvelight distribution uniformityVSAvoidnumber of diaphragm layers

Core Design Contradiction:

Illumination intensityVSQuantity of substance

Solution Approach 1:

The patent extracts and eliminates the need for multiple diaphragm layers by introducing a reflective structure that achieves light mixing through reflection rather than through multiple absorbing and re-emitting layers. This removes unnecessary components while maintaining or improving light distribution uniformity.

Inventive Principle:

Principle #2Taking out (Extraction)

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 effectively compensates for uneven brightness, reduces module thickness, and lowers production costs while enhancing display performance and dynamic range.

Implementation Method 1

The cup-shaped reflecting surface is configured for reflecting a light directly emitted from the chip and a light reflected from the shading element to an area to be filled with light

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS11686897B2Light mixing module, display device having the light mixing module and design method for the light mixing module

Publication Date: 2023.06.27 DURA CHIP (NANTONG) LIMITED

AI summary

A light mixing module, a display device having the light mixing module, and a design method for the light mixing module are provided. The light mixing module includes a main substrate with a printed circuit, and at least one chip-level light emitting unit arranged on the main substrate. The chip-level light emitting unit includes a LED chip, a backlight bracket, a shading element and a supporting element. The backlight bracket is mounted on the main substrate, and the backlight bracket has a cup-shaped reflecting surface surrounding the LED chip. The shading element is suspended right above the LED chip by the supporting element.