Light Diffusion Plate with Organic Dyes for Mini LED Backlight
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Solution Overview
Problem
Conventional light diffusion plates for Mini LED backlight modules face issues with uneven color temperature dispersion, excessive heat generation, and reduced efficiency due to phosphor placement, and the use of toxic cadmium in quantum dot films for generating white light.
Innovation Solution
A light diffusion plate with organic dyes added during the extrusion process to uniformly disperse light and convert blue light into white light, utilizing a foaming extrusion process with micro-bubbles for improved light distribution and temperature resistance, and a nucleating agent to control bubble size for enhanced color gamut and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phosphor glue is applied directly on the LED chip to generate white light, then the manufacturing process is simple, but the color temperature is unevenly dispersed and heat dissipation is poor
Solution Approach 1:
The patent separates the light conversion function from the heat source by placing phosphor particles in a light diffusion plate rather than directly on the LED chip. This segmentation allows the phosphor to be distributed uniformly across a larger area, improving color temperature uniformity while maintaining manufacturing simplicity through integrated plate production.
Solution Approach 2:
The light diffusion plate serves as an intermediary component between the blue LED chip and the final white light output. It contains phosphor particles that convert blue light to other wavelengths while also functioning as a heat dissipation pathway, mediating both optical and thermal management.
2Ease of manufacture
If phosphor is mixed with glue and applied on LED chip, then the manufacturing process is simple, but excessive heat generation occurs and phosphor heat dissipation is poor
Solution Approach 1:
The patent extracts the phosphor from its traditional location on the LED chip and relocates it to the light diffusion plate. This extraction separates the phosphor from the primary heat source, allowing heat to dissipate through the plate's larger surface area and improving thermal management while maintaining simple manufacturing processes.
Solution Approach 2:
The solution transitions from a two-dimensional phosphor layer on the chip surface to a three-dimensional distribution of phosphor particles within the light diffusion plate volume. This dimensional change provides additional thermal pathways and improves heat dissipation efficiency.
3Illumination intensity
If quantum dot film is added to generate white light, then wide color gamut and accurate color control are achieved, but the film is expensive and contains toxic cadmium
Solution Approach 1:
The patent replaces expensive quantum dot materials with conventional phosphor particles that are cheaper and environmentally friendly. While quantum dots offer superior color accuracy, the phosphor-based solution provides a cost-effective alternative that meets practical requirements without toxic cadmium content.
Solution Approach 2:
The patent converts the potential disadvantage of using conventional phosphors (which typically provide narrower color gamut than quantum dots) into a benefit by achieving adequate color performance through optimized phosphor selection and distribution, while eliminating the environmental harm associated with cadmium-based quantum dots.
4Device complexity
If conventional light diffusion plate is used with blue Mini LEDs, then the structure is simple, but color temperature is unevenly dispersed
Solution Approach 1:
The patent applies local quality by distributing phosphor particles with specific characteristics (size, composition, concentration) throughout the light diffusion plate to create localized regions that collectively achieve uniform color temperature. Different areas of the plate contain phosphor configurations optimized for their specific light paths from the Mini LED array.
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 achieves uniform light emission, consistent color temperature, and extended light extraction efficiency while avoiding toxic materials, providing a cost-effective and environmentally friendly method for producing white light in Mini LED backlight modules.
Implementation Method 1
adding organic dyes in the extrusion process of the light diffusion plate to uniformly disperse the organic dyes in the plastic material for converting the blue light emitted by blue Mini LEDs into white light
Implementation Method 2
The plurality of micro-bubbles is dispersed in the plastic substrate and capable of performing at least one of the following functions on the light in the plastic substrate: reflection, refraction or scattering
Implementation Method 3
The plurality of micro-bubbles is dispersed in the plastic substrate and capable of performing at least one of the following functions on the light in the plastic substrate: reflection, refraction or scattering
Implementation Method 4
The plurality of micro-bubbles is dispersed in the plastic substrate and capable of performing at least one of the following functions on the light in the plastic substrate: reflection, refraction or scattering
Implementation Method 5
By adding a nucleating agent in the foaming extrusion process of the light diffusion plate and uniformly mixing and foaming with an extrusion screw section
Data Source
AI summary
A light diffusion plate is configured to be assembled with a blue light source module having blue Mini LEDs to form a white light backlight module. The light diffusion plate is added with organic dyes with light-emission wavelength of 490-650 nm in order to convert the blue light into white light. The light diffusion plate is made by a foaming extrusion process and contains a plurality of micro-bubbles with a size of 60-400 μm and a weight-reduction ratio of 15-25% for improving the uniformity of white light and resolving the MURA problem. The size of micro-bubbles is controlled by reducing the temperature of at the exit end of the T-die head, such that the wavelength of the white light emitted from the light diffusion plate can be narrower to achieve the effect of wider color gamut display.