Integrated Optical Sheet Assembly for Backlight Units
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of backlight units for liquid crystal display devices is complicated due to the separate manufacturing and assembly of prism and diffusion sheets, leading to increased thickness and complexity.
Innovation Solution
An optical sheet assembly is developed where multiple optical sheets with different functions are integrally manufactured and assembled, with specific thickness relationships and patterns to enhance flatness and optical properties, including a first diffusion sheet and second and third condensing sheets with protruding division regions and air gaps, to form a unified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple optical sheets are separately manufactured and joined, then each sheet can be optimized for its specific function, but the manufacturing process becomes complicated and the overall thickness increases
Solution Approach 1:
The patent combines multiple separate optical sheets (diffusion sheet and condensing sheet) into a single integrated optical sheet with a unified base film. The diffusion pattern and condensing pattern are formed on the same base film, eliminating the need for separate manufacturing and assembly processes. This reduces manufacturing complexity while maintaining the optical functions of both patterns.
2Manufacturing precision
If multiple optical sheets are separately manufactured and joined, then each sheet can be optimized for its specific function, but the overall thickness increases
Solution Approach 1:
The patent merges multiple optical sheets into a single integrated structure where the diffusion pattern and condensing pattern coexist on one base film. This eliminates the cumulative thickness of multiple separate sheets and their adhesive layers, achieving a thinner overall assembly while preserving all optical functions.
3Device complexity
If optical sheets are integrally manufactured, then manufacturing complexity is reduced and thickness is decreased, but flatness control becomes more difficult
Solution Approach 1:
The patent applies different patterns (diffusion and condensing) to different regions of the base film, with each pattern optimized for its specific location and function. The diffusion pattern is formed in a first region while the condensing pattern is formed in a second region, allowing each area to have the specific quality needed for its optical function while maintaining overall flatness through proper design.
4Device complexity
If optical sheets are integrally manufactured, then manufacturing complexity is reduced and thickness is decreased, but optical property optimization becomes more difficult
Solution Approach 1:
The patent optimizes optical properties by creating different patterns in different regions of the base film. The diffusion pattern in the first region provides light diffusion functionality, while the condensing pattern in the second region provides light condensing functionality. Each region is independently optimized for its specific optical requirement, maintaining high manufacturing precision despite integral manufacturing.
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
This approach allows for thinner, flatter, and more efficient optical sheet assemblies with improved optical characteristics, reducing manufacturing complexity and enhancing the performance of liquid crystal display devices.
Implementation Method 1
a first optical sheet which includes a first base film and a first optical pattern formed on the first base film, light being incident on the first base film
Implementation Method 2
a first optical sheet which includes a first base film and a first optical pattern formed on the first base film, light being incident on the first base film; a second optical sheet which includes a second base film and a second optical pattern formed on the second base film, the light exiting from the first optical sheet being incident thereon
Data Source
AI summary
Disclosed is an optical sheet assembly comprising: a first optical sheet which comprises a first base film and a first optical pattern formed on the first base film, light being incident on the first base film; a second optical sheet which comprises a second base film and a second optical pattern formed on the second base film, the light exiting from the first optical sheet being incident thereon; and a third optical sheet which comprises a third base film and a third optical pattern formed on the third base film, the light exiting from the second optical sheet being incident thereon, wherein the first to third optical patterns perform light condensing or diffusing function, the first optical sheet is joined with the second optical sheet, and the second optical sheet is joined with the third optical sheet.