Mini-LED Backlight Reflector Height Optimization
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Solution Overview
Problem
The existing direct type backlight devices face a limitation in increasing the thickness of the light reflector, which negatively affects the luminous efficiency due to the top surface of the light reflector being higher than the bottom surface of Mini LEDs, thereby restricting the enhancement of luminous efficiency.
Innovation Solution
A direct type backlight device design featuring a printed circuit board with bump structures and Mini-LEDs, where the light reflector is positioned between adjacent Mini-LEDs, and the bottom surface of the light-emitting layer of each Mini-LED is higher than the top surface of the light reflector, allowing for optimal placement and alignment to enhance reflectivity and luminous efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the thickness of the light reflector is increased to improve reflectivity, then the relative reflectivity is higher, but the top surface of the light reflector becomes higher than the bottom surface of Mini LEDs, causing worse luminous efficiency
Solution Approach 1:
The patent applies local quality by creating different height levels for different components. The light reflector is positioned at a lower height level than the Mini LEDs, with the bottom surface of the light-emitting layer being higher than the top surface of the light reflector. This localized height differentiation allows the light reflector to provide sufficient reflectivity while avoiding interference with the light emission path, thereby resolving the contradiction between improving reflectivity and maintaining luminous efficiency.
2Length of stationary object
If Mini LEDs are used in direct type backlight device to reduce thickness, then the thickness of LCD device is reduced, but the top surface of light reflector being higher than bottom surface of Mini LEDs limits the increase of light reflector thickness
Solution Approach 1:
The patent resolves the contradiction by transitioning from a single-dimensional thickness optimization to a multi-dimensional spatial arrangement. Instead of simply increasing the light reflector thickness in one direction, the invention positions the light reflector and Mini LEDs at different height levels, creating a stepped structure. This dimensional change allows both the thinness of the overall device and the sufficient thickness of the light reflector for high reflectivity to be achieved simultaneously, while maintaining optimal luminous efficiency.
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 configuration increases the luminous efficiency of the direct type backlight device by ensuring the bottom surface of the light-emitting layer is level with or higher than the top surface of the light reflector, thereby improving brightness and reflectivity without increasing the device thickness.
Implementation Method 1
a reflective material (e.g., the light reflector or the light reflective sheet) is usually attached on the direct type backlight device so as to improve the overall brightness
Implementation Method 2
Mini LED is a small-size light emitting diode (LED) with a size of approximately 100 μm
Data Source
AI summary
A direct type backlight device includes a printed circuit board, a light reflector and plural Mini-LEDs. The light reflector and the Mini-LEDs are disposed over the printed circuit board. The light reflector is arranged between at least part of adjacent Mini-LEDs. Each of the Mini-LEDs includes a non-light-emitting layer and a light-emitting layer arranged on the non-light-emitting layer. A bottom surface of the light-emitting layer of each of the Mini-LEDs is higher than a top surface of the light reflector.