Monolithic Diffuser Plate for LCD Backlight Units
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Solution Overview
Problem
Conventional backlight units for LCD devices face durability and reliability issues due to deformation caused by temperature and environmental variations, leading to uneven light distribution and image quality degradation, particularly in portable devices where size and weight reductions compromise the structural integrity of diffuser plates made from flexible materials like acrylic resin.
Innovation Solution
A monolithic diffuser plate integrated with a transparent glass substrate and optical sheets, featuring a hiding diffusion part on the rear surface to enhance hiding power and optical efficiency, while the base substrate's glass material provides resistance to heat and humidity, minimizing thickness and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If acrylic resin is used for the diffuser plate to achieve favorable diffusion property, then light diffusion is improved, but the diffuser plate becomes flexible and susceptible to deflection and deformation by heat and humidity
Solution Approach 1:
The patent uses a composite structure combining acrylic resin diffusion sheets with a rigid support plate (polycarbonate or metal). The acrylic resin provides excellent light diffusion properties while the rigid support plate provides dimensional stability and resistance to heat and humidity, resolving the contradiction between diffusion performance and structural reliability
Solution Approach 2:
The patent changes the physical parameters of the support plate by selecting materials with different thermal expansion coefficients and rigidity values (polycarbonate or metal). This parameter change allows the support plate to maintain dimensional stability under varying temperature and humidity conditions while supporting the flexible acrylic resin diffusion sheet
2Volume of moving object
If the backlight unit size is reduced to minimize bezel size, then product compactness is improved, but the durability and reliability of optical components are degraded
Solution Approach 1:
The patent employs composite materials where the rigid support plate (polycarbonate or metal) provides structural strength and dimensional stability in the compact backlight unit. This rigid backbone protects the optical components from deformation even when the overall unit size is reduced for narrow bezel applications
Solution Approach 2:
The patent segments the diffuser plate into two functional parts: the acrylic resin diffusion sheet for light scattering and the rigid support plate for structural integrity. This segmentation allows each component to perform its specific function optimally while working together in a compact configuration
3Ease of manufacture
If diffuser plate and optical films are mounted separately, then ease of manufacture is improved, but deformation by heat and humidity causes uneven light distribution
Solution Approach 1:
The patent merges the diffusion sheet and support plate into a closely integrated assembly where the rigid support plate maintains fixed distances between optical components. This merging ensures that even though components are manufactured separately, they maintain stable relative positions that prevent deformation-induced light distribution issues
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 solution effectively increases the reliability and optical efficiency of the backlight unit and LCD devices by maintaining structural integrity, ensuring uniform light distribution and improved image quality, even in varying environmental conditions, while reducing product thickness.
Implementation Method 1
a hiding diffusion part integrated on a rear surface of the base substrate that increases a hiding power of the base substrate
Implementation Method 2
a monolithic diffusion sheet part integrated on a front surface of the base substrate
Data Source
AI summary
A monolithic diffuser plate for a backlight unit or a liquid crystal display (LCD) device can include a base substrate made of transparent glass, a monolithic diffusion sheet part integrated on a front surface of the base substrate, and a hiding diffusion part integrated on a rear surface of the base substrate for increasing a hiding power of the base substrate. The monolithic diffuser plate can increase a hiding power for hiding individual light sources in a backlight unit, prevent deformations caused by temperature variations and surrounding environmental factors, and minimize the thickness of a product using the monolithic diffuser plate while also increasing the reliability the product.