Optical Film Structure for Thin High-Brightness Mini-LED Shielding
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Solution Overview
Problem
Existing liquid crystal displays using mini-LEDs or micro-LEDs face challenges in maintaining high brightness while preventing the visibility of the light source shape on the panel and achieving a thin form factor due to the need for thick diffusion sheets.
Innovation Solution
An optical film comprising multiple layers with specific pyramid and prism patterns, including a first sheet with pyramid patterns and a second sheet with prism patterns, laminated through adhesive optical protrusions, to diffuse and concentrate light effectively, enhancing shielding and brightness without thick diffusion sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick diffusion sheet is used to prevent the shape of the light source from being visible on the liquid crystal panel, then shielding performance is improved, but the liquid crystal display device cannot be thinned and brightness is greatly decreased
Solution Approach 1:
The patent divides the diffusion function into multiple thin diffusion sheets with specific refractive indices rather than using one thick diffusion sheet. Each sheet has a refractive index within 1.40-1.60, and by stacking multiple sheets, the total shielding performance is achieved while keeping individual sheet thicknesses small (5-20 μm each), enabling overall device thinning.
Solution Approach 2:
The patent changes the refractive index parameter of the diffusion sheets to optimize both shielding and brightness. By controlling the refractive index within 1.40-1.60 and using multiple sheets with different refractive indices, the system achieves high shielding performance without requiring thick sheets, thus maintaining brightness and enabling device thinning.
2Reliability
If a thick diffusion sheet is used to prevent the shape of the light source from being visible on the liquid crystal panel, then shielding performance is improved, but brightness is greatly decreased
Solution Approach 1:
The patent segments the diffusion function across multiple thin sheets rather than using one thick sheet. This segmentation allows light to pass through multiple interfaces with controlled refraction, achieving shielding through cumulative effect while minimizing total light loss, thus maintaining high brightness.
Solution Approach 2:
The patent uses composite material structure with multiple diffusion sheets having different refractive indices (within 1.40-1.60 range) laminated together. This composite approach creates optimized light interaction at each interface, achieving high shielding performance while minimizing overall light attenuation and maintaining brightness.
3Reliability
If multiple diffusion sheets and prism sheets are laminated to increase shielding degree without using a thick diffusion sheet, then shielding performance is improved, but brightness reduction may occur depending on the laminating configuration
Solution Approach 1:
The patent optimizes the refractive index parameter of each diffusion sheet within 1.40-1.60 and controls the number of sheets (1-3 sheets) to achieve the desired shielding performance. By carefully selecting refractive indices and sheet counts, the system maximizes shielding while minimizing brightness loss from multiple interfaces.
Solution Approach 2:
The patent uses a moderate number of diffusion sheets (1-3 sheets) with optimized refractive indices rather than excessive sheets. This partial action approach achieves sufficient shielding performance without over-diffusing light, thereby avoiding unnecessary brightness reduction.
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 optical film achieves excellent shielding performance and high brightness by diffusing and concentrating light, reducing the visibility of light sources and enabling a thinner backlight unit design.
Implementation Method 1
a pyramid pattern layer where a plurality of pyramid patterns is formed on one surface of the first base portion
Implementation Method 2
a first diffusion layer where a plurality of optical protrusion patterns formed on the other surface of the first base portion
Implementation Method 3
a first prism pattern layer where a plurality of prism patterns is formed on one surface of the second base portion
Data Source
AI summary
An optical film according to various embodiments of the present invention may include a base portion; a pyramid pattern layer wherein a plurality of pyramid patterns having a vertex angle being in the vertex angle range of 60° or larger to 160° or smaller is formed on one surface of the base portion; and a diffusion layer wherein a plurality of optical protrusion patterns formed on the other surface of the base portion. the pyramid pattern layer is formed to have a refractive index greater than or equal to a refractive index of the diffusion layer, and a haze value of the diffusion layer is 15% or higher.