Optical Plate Protrusions for Backlight Luminance Uniformity
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Solution Overview
Problem
Current diffuser plates in backlight modules are costly due to high production costs of prism sheets and limited material selection, leading to complex assembly and reduced luminance uniformity, especially in larger display devices.
Innovation Solution
An optical plate with designed protrusions on its surface, which acts as a diffuser plate, enhancing luminance uniformity by reducing the need for multiple optical films and improving light diffusion and condensation properties, while maintaining a lightweight and thin design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If prism sheets are used to condense light and enhance brightness, then luminance is improved, but production cost increases significantly
Solution Approach 1:
The patent combines the light diffusion function of the diffuser plate with the light condensation function of prism sheets into a single integrated structure. The diffuser plate includes both a diffusion region (with diffuse reflective layer) and a condensation region (with prism structure), eliminating the need for separate prism sheets and reducing production costs while maintaining luminance enhancement benefits
Solution Approach 2:
The diffuser plate is designed to perform multiple functions simultaneously: light diffusion in the diffusion region and light condensation in the condensation region. This multi-functional design replaces multiple specialized components (separate diffuser and prism sheets) with a single universal component, reducing assembly complexity and manufacturing cost
2Illumination intensity
If multiple optical films (diffuser and prism sheets) are used to improve luminance and uniformity, then optical performance is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the diffusion and condensation functions into a single diffuser plate with distinct diffusion and condensation regions. This integration eliminates the need to assemble multiple separate optical films (diffuser sheet + prism sheet), significantly reducing assembly steps and complexity while maintaining the optical performance benefits of both functions
3Ease of manufacture
If conventional diffuser plates are used without integrated condensation function, then manufacturing is simpler, but luminance uniformity deteriorates in larger displays
Solution Approach 1:
The diffuser plate employs local quality by creating distinct diffusion and condensation regions with different optical properties. The condensation region with prism structure is strategically positioned to address luminance uniformity issues in specific areas (particularly important for larger displays), while the diffusion region handles overall light scattering, achieving both manufacturing simplicity and improved luminance uniformity
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 plate with protrusions achieves improved luminance uniformity and reduced manufacturing costs by integrating light diffusion and condensation effects, suitable for large-sized displays, and avoids moiré interference fringes.
Implementation Method 1
The protrusions are formed on and projected from the first surface... a diffuser plate... which diffuses the light coming from a light source and achieves uniform brightness on the screen
Implementation Method 2
one or two prism sheets would be disposed on the diffuser plate or between the diffuser plate and the light guide plate to condense the light from the light guide plate
Data Source
AI summary
An optical plate with protrusions, an optical structure, a backlight module and a display device are provided. The optical plate includes a main body and several protrusions. The main body has a first surface. The protrusions are formed on and projected from the first surface. An area ratio of the protrusions to the first surface is in a range of 0.03˜35%. The protrusions have a pitch in a range of 0.5˜10 mm, and a portion of the first surface other than the protrusions has a first center line mean roughness Ra in a range of 0.01˜0.1 μm.