Light-Emitting Panel Reflection Sheet for Edge Light Uniformity
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Solution Overview
Problem
Existing light-emitting panels suffer from non-uniform light efficiency at the edges of light-emitting devices due to inconsistencies in reflectivity and material properties between the bottom reflective layer and reflection sheet, leading to optical quality issues.
Innovation Solution
A light-emitting panel design featuring a reflection sheet with through-holes that wrap around the edges of light-emitting devices, using a thermally-expandable substrate with a high coefficient of thermal expansion, such as polyoxymethylene resin or polydimethylsiloxane, to minimize gaps and ensure uniform reflectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the through-hole size is increased to improve reflection sheet attaching yield, then attaching yield is improved, but a windowed area is created at edges of light-emitting devices where reflectivity becomes inconsistent
Solution Approach 1:
The reflection sheet uses a thermally-expandable substrate that expands after attachment to reduce the gap between the through-hole edge and light-emitting device edge from initially larger than 0.1 mm to less than 0.1 mm. This thermal expansion process eliminates the windowed area and ensures uniform reflectivity across the entire surface including edges.
2Manufacturing precision
If the gap between reflection sheet through-hole edge and light-emitting device edge is reduced to improve light uniformity, then light efficiency uniformity is improved, but attaching yield decreases
Solution Approach 1:
The reflection sheet is attached with a larger through-hole size first to ensure high attaching yield, then thermal expansion is applied as a preliminary action to reduce the gap to less than 0.1 mm. This sequence allows both high attaching yield and uniform light efficiency to be achieved.
Solution Approach 2:
The thermally-expandable substrate expands after attachment, automatically reducing the gap between the through-hole edge and light-emitting device edge to less than 0.1 mm, thereby achieving uniform light efficiency without compromising attaching yield.
3Adaptability or versatility
If different materials are used for bottom reflective layer and reflection sheet, then each component can be optimized independently, but reflectivity inconsistency arises at the interface
Solution Approach 1:
The thermally-expandable substrate with high thermal expansion coefficient (greater than 60 ppm/°C) expands to reduce gaps and ensure optical contact between the reflection sheet and bottom reflective layer, eliminating reflectivity inconsistency at the interface while allowing independent optimization of each component.
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 reduces the gap between the reflection sheet and light-emitting device edges to less than 0.1 mm, enhancing light uniformity and alleviating non-uniform light efficiency issues.
Implementation Method 1
heating the reflection sheet to a preset temperature so that the reflection sheet expands, wherein the plurality of second through-holes shrink with expansion of the reflection sheet to form a plurality of first through-holes
Data Source
AI summary
Provided is a light-emitting panel comprising a substrate, a plurality of light-emitting device, and a reflection sheet, wherein the plurality of light-emitting devices and the reflection sheet are disposed on the same side of the substrate, the reflection sheet comprises a plurality of first through-holes, which are in one-to-one correspondence with the plurality of light-emitting devices, and the reflection sheet at an edge of the plurality of first through-holes is configured to wrap around an edge of the plurality of light-emitting device, and a gap between an edge of the plurality of first through-holes and an edge adjacent to the plurality of light-emitting devices is less than 0.1 mm, so that a distance between the edge of the plurality of first through holes and the edge of the plurality of light-emitting devices is reduced, and the size and width of the windowed area are reduced.