Mini-LED Backlight Module Splicing Dark Line Elimination
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Solution Overview
Problem
Mini-LED backlight modules for small-sized displays face challenges in cost and thickness, leading to insufficient benefits, and medium-sized displays encounter splicing issues resulting in noticeable dark lines due to size limitations and splicing gaps, affecting image quality.
Innovation Solution
A backlight module is manufactured by splicing a light panel on a reinforcing plate with double-sided tape and using a membrane pressure press or casting process to form a uniform fluorescent film, preventing light blocking and eliminating splicing dark lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mini-LEDs are used for small-sized displays, then high brightness and high contrast are achieved, but cost and thickness increase leading to insufficient benefits
Solution Approach 1:
The backlight module is divided into multiple light panels that are spliced together to form a complete backlight. This segmentation allows the use of mini-LEDs in medium-sized displays where they provide high brightness and contrast benefits, while avoiding the need to use mini-LEDs across all display sizes, thus optimizing cost-effectiveness.
2Illumination intensity
If mini-LEDs are used for medium-sized displays, then high brightness and high contrast are achieved, but splicing is required due to machine size limitations, causing splicing gaps and dark lines
Solution Approach 1:
A reinforcing plate is spliced and fixed to the light panel before the fluorescent film is formed. This preliminary structural preparation ensures that subsequent membrane pressure pressing or casting processes can form a uniform fluorescent film across spliced boundaries, preventing light blocking and dark line formation at splice locations.
Solution Approach 2:
The patent applies membrane pressure pressing or casting processes to change the physical state and uniformity of the fluorescent film formation. By controlling these processing parameters, a uniform fluorescent film is achieved across spliced light panels, eliminating splicing dark lines while maintaining high brightness performance.
3Area of stationary object
If splicing is used to assemble light panels, then medium-sized displays can be manufactured, but splicing dark lines appear affecting image quality
Solution Approach 1:
The reinforcing plate is spliced and fixed to the light panel structure before fluorescent film formation. This preliminary action creates a stable foundation that enables subsequent uniform fluorescent film application across splice boundaries, allowing medium-sized displays to be manufactured without splicing dark lines affecting image quality.
Solution Approach 2:
By applying membrane pressure pressing or casting processes, the physical parameters of fluorescent film formation are optimized to ensure uniformity across spliced areas. This enables the production of medium-sized displays with high image quality, free from splicing dark lines.
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
This method improves image quality by ensuring uniform light transmission across the entire surface, eliminating splicing dark lines and enhancing the display's brightness and contrast.
Implementation Method 1
splicing a light panel on a reinforcing plate and fixing it with a double-sided tape
Implementation Method 2
performing a membrane pressure press or a casting process on the backlight module, forming the fluorescent film of the mini-LED as a whole surface structure
Data Source
AI summary
The present disclosure provides a backlight module and a method of manufacturing the backlight module. Through splicing a light panel on a reinforcing plate and fixing with a double-sided tape, and then performing a membrane pressure press or a casting process to the backlight module, forms a fluorescent film of mini-LED as a whole surface structure, in a bid to prevent waveguide blocking light in propagation of the fluorescent film, thereby improving a problem of splicing dark line.