Micro-structure Film for Light Emitting Module Uniformity
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Solution Overview
Problem
Conventional light emitting modules require multiple optical films to reduce the mura phenomenon, increasing thickness and cost, and there is a need to improve optical efficiency while minimizing the number of light sources and optical films used.
Innovation Solution
A micro-structure film with convex or concave micro-structures on its surfaces, and a light emitting module with a package layer incorporating these micro-structures, which disperses light and reduces the need for additional optical films, enhancing optical efficiency and allowing for fewer light sources per unit area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If diffusion plates or optical films are stacked to homogenize light and reduce mura phenomenon, then luminous uniformity is improved, but module thickness increases
Solution Approach 1:
The patent segments the optical film into multiple micro-structures (convex or concave) distributed across the film surface. Each micro-structure independently contributes to light scattering and homogenization, collectively achieving uniform luminosity without requiring multiple stacked films, thus reducing overall thickness while maintaining luminous uniformity
Solution Approach 2:
The patent transitions from a flat, two-dimensional optical film surface to a three-dimensional surface with convex or concave micro-structures. This dimensional change enables enhanced light scattering and homogenization effects within a thinner profile, as the vertical dimension of the micro-structures provides additional optical path length without increasing the film's overall thickness
2Length of stationary object
If quantity of point light sources is increased to reduce module thickness, then module thickness is reduced, but costs increase
Solution Approach 1:
The patent extracts the light homogenization function from the light sources themselves and transfers it to the optical film with micro-structures. This allows the use of fewer light sources while maintaining uniform luminosity, as the optical film compensates for the reduced number of sources by actively scattering and redistributing light across the module surface
Solution Approach 2:
The patent changes the physical parameters of the optical film by introducing convex or concave micro-structures with specific geometric characteristics (depth, diameter, spacing). These parameter changes enable the film to achieve superior light homogenization performance, allowing reduction in light source quantity while maintaining uniformity and reducing thickness
3Stability of the object's composition
If multiple optical films are used to achieve good luminous uniformity, then luminous uniformity is improved, but optical efficiency decreases
Solution Approach 1:
The patent merges multiple optical functions (light scattering, homogenization, and directional control) into a single optical film with integrated micro-structures. This consolidation eliminates the need for multiple separate films, reducing cumulative optical losses at each interface while maintaining comprehensive light management capabilities, thus improving optical efficiency without sacrificing luminous uniformity
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-structure film and module design improves optical efficiency, reduces the number of light sources required, and decreases module thickness, maintaining good luminous uniformity even without additional optical films, as demonstrated by simulation and optical measurement results.
Implementation Method 1
a plurality of micro-structures are uniformly distributed on an other side of the package layer opposite to the first surface... The micro-structure is convex or concave... disperses light and reduces the need for additional optical films
Data Source
AI summary
A micro-structure film and a light emitting module are disclosed. A plurality of micro-structures with at least one predefined shape are uniformly distributed on at least one of surfaces of two opposite sides of the micro-structure film. The light emitting module includes a substrate, a plurality of light sources, and a package layer. The substrate has a first surface. The plurality of light sources are arranged on the first surface. The package layer is arranged on the first surface to contact with and cover the light sources. A plurality of micro-structures with at least one predefined shape are uniformly distributed on an other side of the package layer opposite to the first surface.