LED Display Optical Blending With Diffuser Film and Black Resin
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Solution Overview
Problem
High-resolution LED displays suffer from brightness and color shift issues due to variations in light diffusion agent density in molding layers, leading to uneven brightness and color shift when multiple panels are assembled, especially at varying viewing angles.
Innovation Solution
A prefabricated diffuser film with controlled light diffusion agent density and thickness is applied to the LED display panel, filling gaps between light emitting elements with black resin to form a planar surface, and affixing a transparent resin layer before applying the diffuser film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a molding layer with light diffusion agent is applied to the LED display panel surface, then color shift is reduced, but brightness uniformity deteriorates due to density variations in the light diffusion agent
Solution Approach 1:
The patent separates the light diffusion function from the molding layer by applying a prefabricated diffuser film as a distinct layer. This segmentation allows the diffuser film to be manufactured with precise, uniform light diffusion agent density independent of the molding layer variations, thereby maintaining color shift reduction while achieving brightness uniformity across the display panel
Solution Approach 2:
The patent uses a composite structure combining a transparent molding layer with a separate prefabricated diffuser film layer. The diffuser film contains light diffusion agents embedded in a transparent substrate, creating a composite material system that provides both color shift reduction and uniform light diffusion properties that cannot be achieved with the molding layer alone
2Reliability
If the density of light diffusion agent in molding layer is increased to reduce color shift, then brightness uniformity worsens causing some panels to appear too bright
Solution Approach 1:
The patent changes the physical form and distribution parameters of the light diffusion agent by transferring it from a mixed molding layer to a controlled prefabricated film. The diffuser film maintains the light diffusion agent concentration needed for color shift reduction while achieving uniform spatial distribution and consistent optical properties across all display panels, eliminating brightness non-uniformity
3Ease of manufacture
If multiple LED display panels with slightly different molding layers are assembled together, then manufacturing flexibility is improved, but brightness and color shift uniformity across the display wall deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-fabricating diffuser films with standardized, precise light diffusion agent densities before assembly. Each display panel receives an identical diffuser film layer that compensates for minor variations in the molding layer, ensuring uniform brightness and color across the entire display wall while maintaining assembly flexibility
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 reduces color shift and brightness variations across different viewing angles, expanding the viewing angle range without significant color shift, and provides uniform illumination.
Implementation Method 1
a prefabricated diffuser film containing a light diffusion agent
Implementation Method 2
filling the plurality of gaps with a black resin
Data Source
AI summary
A method for assembling an LED display includes the steps of: preparing a prefabricated diffuser film containing a light diffusion agent; mounting a plurality of light emitting elements on a substrate, thereby forming a plurality of gaps among the plurality of light emitting elements; filling the plurality of gaps with a black resin to form a planar surface composed of top surfaces of the plurality of light emitting elements and top surfaces of the black resin in the plurality of gaps; applying a transparent resin layer over the planar surface; and affixing the prefabricated diffuser film on the transparent resin layer. The resulting LED display has a plurality of light emitting elements surrounded by a black resin to form a checkered surface, a transparent resin layer affixed to the checkered surface; and a diffuser film affixed to the transparent resin layer by an adhesive.