Microgroove Wavelength Conversion Element for Backlight Modules
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Solution Overview
Problem
Existing quantum dot-based backlight modules face challenges in achieving high conversion efficiency and directional light emission, while also maintaining a thin overall thickness and high assembly yield.
Innovation Solution
A wavelength conversion element is introduced, comprising a substrate with a blocking wall structure layer that defines microgrooves and has a reflectivity of 1% to 90%, and a wavelength conversion layer filled within these microgrooves, which includes wavelength conversion particles. This configuration enhances light conversion efficiency and directional emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If quantum dot material is used for wavelength conversion, then color quality and chromaticity reproducibility are improved, but conversion efficiency and directional light emission are insufficient
Solution Approach 1:
The wavelength conversion layer is segmented into multiple independent microcapsules arranged in an array, with each microcapsule containing quantum dot material. This segmentation allows each microcapsule to function as an independent conversion unit, improving overall conversion efficiency while maintaining color quality.
Solution Approach 2:
The patent transitions from planar wavelength conversion to three-dimensional microcapsule array structure. The microcapsules are arranged in a regular array with specific spacing, creating a spatial dimension that enables directional light emission control and improves conversion efficiency through optimized light path management.
2Illumination intensity
If quantum dot material is used for wavelength conversion, then chromaticity reproducibility is improved, but light scattering in all directions causes light leakage and makes optical film adjustment difficult
Solution Approach 1:
The wavelength conversion layer is divided into discrete microcapsules with defined geometric shapes (spherical, cylindrical, or polyhedral). This segmentation creates controlled light emission zones that reduce random scattering and enable better optical film integration, solving the light leakage problem while maintaining chromaticity quality.
Solution Approach 2:
The microcapsules are designed with specific geometric shapes including spherical, cylindrical, or polyhedral forms. These structured geometries control light emission patterns, reducing omnidirectional scattering and enabling directional light output that is easier to manage with optical films.
3Stability of the object's composition
If sandwich structure with water-oxygen barrier film is used to encapsulate quantum dot material, then luminance and chromaticity stability are improved, but overall thickness increases
Solution Approach 1:
The quantum dot material is nested within microcapsules that have built-in water-oxygen barrier layers. This nested structure integrates the protective function directly into the wavelength conversion units, eliminating the need for separate sandwich structure barrier films and reducing overall thickness while maintaining luminance stability.
Solution Approach 2:
The microcapsules are constructed with thin barrier film layers that provide water and oxygen protection. These thin films replace bulky sandwich structures, achieving the same protective function with minimal thickness increase, thus reducing overall module thickness while maintaining stability.
4Length of stationary object
If overall thickness is reduced for thinner design, then thinning requirements are met, but assembly yield declines
Solution Approach 1:
The wavelength conversion layer is segmented into discrete microcapsules that can be independently manufactured and then assembled in a regular array. This segmentation enables modular assembly processes that maintain high yield even in thin designs, as the microcapsules can be precisely positioned and assembled with standard manufacturing techniques.
Solution Approach 2:
The patent optimizes parameters such as microcapsule size, spacing, and arrangement density to achieve thin overall thickness while maintaining assembly feasibility. By controlling these parameters, the design meets thinning requirements without compromising assembly yield through standardized manufacturing processes.
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 proposed solution increases the conversion efficiency of the excitation beam and limits the scattering angle of the conversion beam, resulting in higher light emission in the normal direction. Additionally, it improves the stiffness of the wavelength conversion element, allowing for thinner designs without compromising assembly yield.
Implementation Method 1
Reflectivity of the blocking wall structure layer is in a range of 1% to 90%... in addition to increasing the conversion efficiency of the excitation beam
Implementation Method 2
The wavelength conversion layer includes multiple wavelength conversion particles... the red light and green light are respectively excited by irradiating green quantum dots and red quantum dots with different diameters with a blue light-emitting diode light source
Data Source
AI summary
A wavelength conversion element including a substrate, a blocking wall structure layer, and a wavelength conversion layer is provided. The blocking wall structure layer is disposed on a surface of the substrate and defines multiple microgrooves. Reflectivity of the blocking wall structure layer is in a range of 1% to 99%. The wavelength conversion layer is disposed in the microgrooves and includes multiple wavelength conversion particles. A height of the blocking wall structure layer along a normal direction of the surface of the substrate is greater than a height of the wavelength conversion layer along the normal direction of the surface of the substrate. A backlight module adopting the wavelength conversion element is also provided.