Paper Fiber Diffusion Sheet for Backlight Modules
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Solution Overview
Problem
Current diffusion sheets in backlight modules, made from polyethylene terephthalate, have high preparation costs and are heavy due to the use of this material for substrates and surface coatings.
Innovation Solution
A diffusion sheet comprising a paper fiber layer with light-transmissive protective layers on both sides, which allows for efficient light diffusion while reducing material costs and weight, using paper fibers and optional organic film layers with diffusing particles for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyethylene terephthalate is used for substrate and surface coating, then the diffusion sheet has good light transmission and durability, but the preparation cost is high and the weight is heavy
Solution Approach 1:
The patent uses a composite structure combining paper fiber layer with cellulose acetate butyrate coating layer. This composite material approach achieves the desired light transmission and durability properties while significantly reducing weight and cost compared to using polyethylene terephthalate throughout.
Solution Approach 2:
The patent replaces expensive polyethylene terephthalate with cheaper paper fiber substrate coated with cellulose acetate butyrate. This substitution uses more economical materials that can achieve the required performance at lower cost and reduced weight.
2Reliability
If polyethylene terephthalate is used for substrate and surface coating, then the diffusion sheet has good light transmission and durability, but the preparation cost is high
Solution Approach 1:
The patent employs a composite structure with paper fiber substrate and cellulose acetate butyrate coating layer. This combination achieves the required optical and mechanical properties while using more cost-effective materials, thereby reducing preparation costs.
Solution Approach 2:
The patent substitutes expensive polyethylene terephthalate with cheaper alternatives (paper fiber and cellulose acetate butyrate) that can deliver comparable performance at lower material and manufacturing costs.
3Illumination intensity
If spherical particles are uniformly distributed on the substrate, then uniform light diffusion is achieved, but the device complexity increases
Solution Approach 1:
The patent uses a paper fiber substrate with inherent porous structure that naturally diffuses light uniformly without requiring additional spherical particles or complex surface treatments. The porous network of paper fibers provides sufficient light diffusion while keeping the structure simple.
Solution Approach 2:
The patent removes the need for spherical particles and complex multi-layer coatings by utilizing the inherent light-diffusing properties of the paper fiber substrate itself, thereby simplifying the overall structure while maintaining uniform light diffusion.
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 paper fiber-based diffusion sheet provides uniform light diffusion, reduces production costs, and minimizes weight, making it suitable for use in backlight modules and liquid crystal display devices.
Implementation Method 1
Light can be refracted many times by the substrate, the spherical particles and the surface coating layer in a process of passing through the diffusion sheet, so as to produce a uniform diffusing effect
Implementation Method 2
The spherical particles are different in light transmission and refraction coefficient from the substrate... Light can be refracted many times by the substrate, the spherical particles and the surface coating layer
Data Source
AI summary
A diffusion sheet, a backlight module and a liquid crystal module are disclosed. The diffusion sheet comprises a paper fiber layer (1) with surfaces on two sides both disposed with a light-transmissive protection layer (2, 3). The diffusion sheet can well diffuse light passing through the diffusion sheet, and hence improve uniformity of light passing through the diffusion sheet. A paper fiber layer (1) is employed in the diffusion sheet for diffusion, which makes a paper fiber layer (1) be prepared at a low cost and have a small weight, and hence reduce the preparation cost and weight of a diffusion sheet to provided convenience for transfer of a product.