Backlight Diffuser Refractive Convex Structures
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Solution Overview
Problem
Current diffusion films in backlight modules suffer from light absorption and reduced light transmittance due to chemical particle properties, leading to uneven light distribution and increased manufacturing costs, as well as inefficiencies in light utilization and distribution.
Innovation Solution
A diffuser with a transparent substrate and refractive convex optical structures on its exit surface, designed to refract light and redistribute intensity, using materials like PMMA, PC, or their combinations, with optical structures having conical or hemispherical cross-sections, to achieve uniform light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If chemical grains are added to the film substrate as scattering particles, then light scattering is achieved, but light absorption increases and light transmittance is reduced
Solution Approach 1:
The invention extracts and removes the chemical scattering particles from the diffusion film structure. Instead of using chemical grains dispersed in the resin layer, the patent uses a hologram-based technique that records phase distributions directly onto the substrate surface, eliminating the need for chemical particles and thereby reducing light absorption while maintaining scattering functionality.
Solution Approach 2:
The invention replaces the chemical-based scattering mechanism with a physical/optical approach. By using hologram technology to create micro-relief structures on the substrate surface, the patent substitutes chemical particle scattering with physical light diffraction and refraction through the recorded phase patterns, achieving scattering without the light absorption penalties of chemical grains.
2Ease of manufacture
If chemical processes are used for manufacturing diffusion films, then scattering particles can be dispersed, but manufacturing time increases and cost is higher
Solution Approach 1:
The invention replaces chemical manufacturing processes with a physical hologram-based manufacturing approach. By using optical exposure and development techniques to directly record phase distributions onto the substrate, the patent eliminates time-consuming chemical particle dispersion processes while achieving the desired scattering effect through the holographic micro-structures.
3Illumination intensity
If light scattering is random, then diffusion is achieved, but light utilization is poor and light is wasted
Solution Approach 1:
The invention applies local quality by creating non-uniform, position-dependent scattering characteristics through the holographic phase distribution. Instead of random scattering throughout the entire film, the patent records specific phase patterns at different locations that guide and control light scattering in predetermined directions, optimizing light distribution while improving utilization efficiency.
Solution Approach 2:
The invention changes the scattering parameter from random to controlled by using holographic phase distributions. The recorded phase patterns modify the local optical properties of the substrate, transforming the scattering behavior from unpredictable random diffusion to controlled directional redistribution, thereby improving light utilization while maintaining diffusion effects.
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 diffuser effectively extends the space distribution of light sources, reducing uneven light intensities and enhancing light utilization by refracting light rays, resulting in a uniform light output with improved efficiency and cost-effectiveness.
Implementation Method 1
Each optical structure is dented from the exit surface to the interior of the transparent substrate and forms a refractive convex within the transparent substrate... the included angle between the tangent to the refractive convex edge and the normal to the exit surface lead an incident light ray from the light sources to refract and deviate from the normal to the refractive convex through the refractive convex
Data Source
AI summary
A diffuser used in a backlight module including a plurality of light sources is disclosed. The diffuser according to the present invention makes a uniform light output. The diffuser includes a transparent substrate and a plurality of optical structures. The transparent substrate has an entrance surface and an exit surface. The plurality of optical structures is disposed on the exit surface, each optical structure is dented from the exit surface to the interior of the transparent substrate and forms a refractive convex within the transparent substrate, and each refractive convex corresponds to one of the plurality of the light sources. The maximum value of the included angle between the tangent to the refractive convex edge and the normal to the exit surface is smaller than 30 degrees, such that an incident light ray from the light sources refracts and deviates from the normal to the refractive convex through the refractive convex.