Diffuser Sheet Beads Pores Backlight Thickness
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Solution Overview
Problem
In LCD display devices with direct-type backlight units, reducing thickness leads to shortened optical distance between the diffuser sheet and light source, resulting in lattice mura and decreased opacity, while maintaining impact resistance and image quality is a challenge.
Innovation Solution
A diffuser sheet with a base layer containing dispersed beads and pores, combined with first and second skin layers, is used to maintain high opacity and impact resistance, improving image quality without deteriorating luminance or mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the direct-type backlight unit is reduced, then the device achieves lightweight and thin design, but the optical distance between the diffuser sheet and light source is shortened, resulting in lattice mura and reduced opacity
Solution Approach 1:
The patent introduces a porous layer with controlled pore size (1-10 μm) and porosity (10-50%) between the light source and diffuser sheet. These pores scatter and diffuse light effectively, maintaining high opacity and preventing lattice mura even when the overall backlight unit thickness is reduced to 5-15mm.
Solution Approach 2:
The patent creates a composite structure combining the porous layer with the diffuser sheet and light guide plate. This composite approach allows the porous layer to compensate for the reduced optical distance, maintaining light diffusion quality while enabling thinner overall device design.
2Object-generated harmful factors
If the distance between the diffuser sheet and light source is increased to reduce lattice mura, then opacity is improved, but the backlight unit thickness increases
Solution Approach 1:
The porous layer provides enhanced light scattering capability within a compact thickness (10-50 μm), achieving high opacity and lattice mura prevention without requiring increased overall backlight unit thickness. The controlled pore structure maximizes light diffusion efficiency in a thin profile.
Solution Approach 2:
The patent optimizes specific parameters of the porous layer including pore size (1-10 μm), porosity (10-50%), and thickness (10-50 μm) to achieve maximum light scattering efficiency. These parameter optimizations allow high opacity performance within a minimal thickness increase.
3Object-generated harmful factors
If the number of light sources is reduced to improve price competitiveness, then cost is reduced, but maintaining high opacity and image quality becomes more difficult
Solution Approach 1:
The porous layer enhances light scattering and diffusion efficiency, allowing fewer light sources to achieve the same overall opacity and uniformity. This compensates for the reduced number of light sources while maintaining image quality and preventing lattice mura.
Solution Approach 2:
By optimizing the porous layer parameters (pore size, porosity, thickness), the patent maximizes light diffusion efficiency per unit area, allowing the system to achieve high opacity with reduced light source quantity, thereby improving price competitiveness.
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 sheet achieves high opacity and impact resistance by controlling the content ratio of beads and pores in the base layer, enhancing image quality and maintaining luminance, even when the number of light sources is reduced, thus improving price competitiveness.
Implementation Method 1
a base layer, the base layer including: a base resin, a plurality of beads dispersed in the base resin, and a plurality of pores dispersed in the base resin
Data Source
AI summary
A diffuser sheet and display device having the same are provided. The diffuser sheet includes a base layer, a first skin layer on an upper surface of the base layer, and a second skin layer on a lower surface of the base layer. The base layer includes a base resin, a plurality of beads dispersed in the base resin, and a plurality of pores dispersed in the base resin.