Optical Structure Film for Uniform LED Backlight
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Solution Overview
Problem
Current direct-lit type LED backlight modules face issues of uneven screen display, increased costs, and thickness due to the use of multiple optical films, which complicates manufacturing and increases production costs.
Innovation Solution
An optical structure film with specific microstructures arranged in arrays on a substrate, enhancing light splitting and homogenizing effects, and a light source module design that reduces the number of light-emitting elements while maintaining uniformity without noticeable bright spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple optical films (diffusion board, structure diffusion films, lower diffusion sheet, prism sheet, DBEF) are stacked to improve screen uniformity, then screen uniformity is improved, but device complexity, manufacturing cost, and thickness increase
Solution Approach 1:
The patent combines multiple optical films (diffusion board, structure diffusion films, lower diffusion sheet, prism sheet, DBEF) into a single integrated optical structure film. The film includes multiple functional layers with different microstructures (first microstructures for light extraction, second microstructures for light homogenization) that perform the functions of separate films simultaneously, thereby reducing device complexity while maintaining screen uniformity.
Solution Approach 2:
The optical structure film is designed to perform multiple functions simultaneously: light extraction enhancement through first microstructures, light homogenization through second microstructures, and reduction of bright spots. This multi-functional design eliminates the need for separate specialized films for each function, reducing the overall number of components while achieving the same or better performance.
2Stability of the object's composition
If multiple optical films are stacked to improve screen uniformity, then screen uniformity is improved, but manufacturing cost increases
Solution Approach 1:
By merging multiple optical films into a single integrated structure, the patent reduces the total number of manufacturing steps, material purchases, and assembly operations. Although the single film has complex microstructures, it eliminates the need to produce, quality-test, and assemble multiple separate films, thereby reducing overall manufacturing cost.
Solution Approach 2:
The multi-functional optical structure film replaces multiple specialized films, reducing the total material cost and assembly cost. The film's ability to perform light extraction, homogenization, and bright spot reduction in a single component eliminates the need for separate functional films, simplifying the bill of materials and reducing manufacturing complexity.
3Stability of the object's composition
If multiple optical films are stacked to improve screen uniformity, then screen uniformity is improved, but thickness increases
Solution Approach 1:
The patent integrates the functions of multiple thick optical films into a single film with optimized microstructures. The first and second microstructures are designed with specific dimensions and configurations that achieve the required optical performance in a compact form, significantly reducing the total thickness compared to stacking multiple separate films.
4Device complexity
If the number of light-emitting elements is reduced to lower cost and complexity, then device complexity is reduced, but screen uniformity deteriorates with noticeable bright spots
Solution Approach 1:
The patent extracts and addresses the bright spot issue separately through the optical structure film's microstructures, which are designed to redirect and homogenize light from fewer LED elements. The first microstructures extract light efficiently while the second microstructures prevent localized bright spots, allowing reduced LED density without compromising uniformity.
Solution Approach 2:
The optical structure film applies different microstructure configurations at different locations to address local light distribution issues. The first and second microstructures are strategically positioned and dimensioned to handle specific light patterns from the LED array, ensuring uniform output even with fewer light-emitting elements by compensating for local brightness variations.
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 achieves improved screen uniformity, reduces manufacturing complexity and costs, and decreases the overall thickness of the light source module by optimizing the arrangement of microstructures and light-emitting elements.
Implementation Method 1
The first microstructure includes two first inclined planes opposite to each other and two second inclined planes connected to the two first inclined planes... A first included angle between the first inclined plane and the first surface is greater than a second included angle between the second inclined plane and the first surface
Implementation Method 2
The first microstructure includes two first inclined planes opposite to each other and two second inclined planes connected to the two first inclined planes
Implementation Method 3
The second microstructure has a top surface with a concave shape. The top surface includes four curved surfaces and four third inclined surfaces respectively connected to the four curved surfaces
Data Source
AI summary
A light source module including an illuminant board and an optical structure film is provided. The optical structure film is arranged on the illuminant board and includes multiple first microstructures on a first surface and multiple second microstructures on a second surface. Each of the first microstructures includes two first inclined planes opposite to each other and two second inclined planes opposite to each other. An included angle between the first inclined plane and the first surface is greater than an included angle between the second inclined plane and the first surface. Each of the second microstructures has a top surface with a concave shape, and the top surface includes four curve surfaces and four third inclined surfaces.