Display Lens Alignment for Higher Brightness and Lower Power
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
LED displays face issues with insufficient brightness due to large light emission angles and increased power consumption when intensity is increased, along with potential damage from high temperatures during manufacturing, leading to decreased product yield and higher costs.
Innovation Solution
A display device design featuring a circuit substrate with light emitting units and light collection structures, where the centers of emitting units and collection structures are positioned to satisfy specific distance and diameter relationships, and a manufacturing method involving separate assembly of lens and panel substrates to enhance light collection and reduce thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the light intensity is increased by increasing the current, then the brightness is improved, but the power consumption will increase
Solution Approach 1:
The patent divides the light collection function into multiple light collection structures (lens substrates) that are separately positioned relative to each light emitting unit. This segmentation allows optimized light gathering from different angles without requiring excessive current, thereby improving brightness efficiency while controlling power consumption.
Solution Approach 2:
The light collection structures act as intermediary optical elements between the light emitting units and the display output. These intermediaries redirect and concentrate light that would otherwise be emitted at large angles, improving brightness without increasing the electrical current and thus avoiding increased power consumption.
2Productivity
If high temperature is used during the manufacturing process, then the manufacturing efficiency is improved, but the light emitting diodes may be damaged
Solution Approach 1:
The patent separates the manufacturing process into distinct stages: the light collection structures are formed on a lens substrate independently, and the light emitting units are mounted on a circuit substrate separately. This segmentation allows the lens substrate to undergo high-temperature processes without exposing the sensitive LED chips to damaging temperatures, thereby maintaining both manufacturing efficiency and product yield.
Solution Approach 2:
The light emitting diodes are extracted from the high-temperature manufacturing environment by mounting them separately on the circuit substrate after the lens substrate has been prepared. This extraction protects the LEDs from thermal damage while allowing the lens substrate to be manufactured with high-temperature processes for improved manufacturing efficiency.
3Adaptability or versatility
If the light emission angle is large, then the light distribution is improved, but the brightness becomes insufficient
Solution Approach 1:
Light collection structures serve as optical intermediaries that capture light emitted at large angles and redirect it toward the viewing direction. This maintains good light distribution across different viewing angles while concentrating the light intensity in the forward direction, thereby improving brightness without sacrificing distribution characteristics.
Solution Approach 2:
The patent addresses the brightness issue by adding a spatial dimension to light collection - using three-dimensional lens structures with specific curvature and depth. These structures collect light from a wide angular range and refract it through an additional optical path, effectively converting wide-angle emission into concentrated forward light without compromising distribution.
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 enhances light output intensity while reducing power consumption and production costs, improving product yield by minimizing thermal damage and chromatic aberration.
Implementation Method 1
a plurality of light collection structures including a first light collection structure and a second light collection structure, wherein the first light collection structure corresponds to the first light emitting unit, and the second light collection structure corresponds to the second light emitting unit
Data Source
AI summary
A display device includes a circuit substrate, first and second light emitting units disposed on the circuit substrate, and first and second light collection structures. The first light collection structure corresponds to the first light emitting unit, and the second light collection structure corresponds to the second light emitting unit. In a top-view direction, there is a first distance between the first light emitting unit and the first light collection structure, there is a second distance between the second light emitting unit and the second light collection structure, the first light collection structure has a first diameter, and the first distance, the second distance and the first diameter satisfy: |C1−C2|≤⅕×D1, where C1 represents the first distance, C2 represents the second distance, D1 represents the first diameter, and C1 and C2 are each not equal to zero.