Micro-molded Sheet for Backlight Uniformity
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Solution Overview
Problem
Existing backlight module technologies face challenges in achieving uniform luminance distribution and concealing LED lamp arrangements while maintaining luminance, as prior-art methods struggle with rigidity, distortion, and light loss due to the use of nano-particles on hard light guide plates and micro-lens formation.
Innovation Solution
A micro-molded sheet with a transparent base material layer, a thin coating containing nano-particles and adhesive, and a micro-molded array layer is developed, providing enhanced rigidity, diffusing effects, and concealment of defects to reduce luminance loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single layer of semispherical patterns is arranged into a column by means of a UV adhesive to form a microlens, then the structure is simple and easy to manufacture, but it fails to conceal the haze of the arrangement mode of the LED lamps and causes loss of luminance
Solution Approach 1:
The patent applies composite materials by combining multiple layers with different functions: a base material layer for structural support, a functional layer containing scattering particles for light diffusion and haze concealment, and a microlens array layer for light concentration. This composite structure resolves the contradiction by integrating both manufacturing simplicity and luminance preservation in a single integrated component rather than separate layers.
Solution Approach 2:
The patent implements local quality by creating regions with different optical properties within the same sheet. The functional layer contains scattering particles distributed in specific concentrations to conceal LED arrangement haze in certain areas, while the microlens regions maintain high light transmission for luminance preservation. This localized functional differentiation resolves the contradiction between concealing haze and maintaining brightness.
2Illumination intensity
If nano-particles are applied on the surface of a hard light guide plate, then the diffusing effect is enhanced, but it is relatively difficult to uniformly apply the nano-particle layer and requires chemical deposition
Solution Approach 1:
The patent applies parameter changes by transitioning from a hard light guide plate surface to a flexible base material layer surface. This change in the substrate parameter (from hard to flexible) enables much easier and more uniform application of the functional layer containing scattering particles, eliminating the need for complex chemical deposition processes while maintaining the light diffusion effect.
Solution Approach 2:
The patent introduces a flexible base material layer as an intermediary between the light guide plate and the scattering particles. This intermediary layer provides a more suitable surface for uniform particle distribution and simplifies the manufacturing process, resolving the contradiction between achieving good diffusion effect and ease of manufacture.
3Weight of moving object
If a micro-molded sheet is made ultrathin and lightweight, then the weight and thickness are reduced, but the rigidity may be compromised
Solution Approach 1:
The patent uses composite materials with a base material layer providing structural rigidity and functional layers adding optical properties. This composite construction allows the sheet to be ultrathin and lightweight while maintaining sufficient rigidity through the structural support of the base layer, resolving the contradiction between weight reduction and rigidity maintenance.
Solution Approach 2:
The patent segments the sheet into multiple functional layers, each with specific thickness and properties. The base material layer provides rigidity, while the functional layers are kept thin to minimize weight. This segmentation allows optimization of each layer's thickness for its specific function, achieving both lightweight and rigid characteristics simultaneously.
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 micro-molded sheet achieves improved rigidity, ultrathin, and lightweight properties, effectively concealing defects and maintaining luminance while enhancing brightness and diffusing performance.
Implementation Method 1
a coating, which is formed on an upper surface of the base material layer and contains an adhesive and nano-particles
Implementation Method 2
a micro-molded array layer, which is disposed on an upside of the coating
Data Source
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Figure 5
AI summary
A micro-molded sheet (20) for backlight module, includes: a base material layer (21) formed from transparent material; a coating (22), which comprises adhesive (22b) and nano-particles (22a), formed on the upper surface of the base material layer (21); and a micro-molded array layer (23) mounted on the upside of the coating (22).