Prism Sheet Heat Resistance Backlight Unit
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Solution Overview
Problem
Prism sheets in backlight units for LCD devices face deformation and scratching issues due to heat and physical impacts, leading to reduced functionality.
Innovation Solution
A prism sheet with a heat-resistant coating layer made of resin and beads is developed, which enhances thermal stability and scratch resistance by scattering and refracting light, while maintaining the base film and prisms for light condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional prism sheet is used in a backlight unit, then the structure is simple and easy to manufacture, but the prism sheet deforms and rumpled by heat generated from the light source, leading to deterioration of function
Solution Approach 1:
The patent applies composite materials by combining a base film with heat-resistant inorganic particles (such as alumina, silica, or boehmite) dispersed within the polymer matrix. This composite structure provides both the optical properties needed for prism functionality and the thermal stability required to resist deformation under heat from the light source, directly resolving the contradiction between temperature resistance and functional stability.
2Strength
If the prism sheet is made thinner to reduce impact, then the structure is simpler, but the prism sheet is easily scratched by slight impact
Solution Approach 1:
The patent incorporates heat-resistant inorganic particles (alumina, silica, boehmite) as reinforcing fillers within the base film matrix. These particles act as reinforcement agents that significantly enhance the scratch resistance and mechanical strength of the prism sheet, allowing it to withstand slight impacts without scratching while maintaining a relatively simple single-layer structure rather than requiring multiple protective layers.
3Strength
If a protection sheet is added to prevent scratching, then the scratch resistance is improved, but the structure becomes more complex and viewing angle is narrowed
Solution Approach 1:
The patent extracts the protective function from a separate protection sheet layer and integrates it directly into the base film by incorporating heat-resistant inorganic particles. This eliminates the need for an additional protection sheet layer, maintaining scratch resistance while simplifying the overall structure and avoiding the viewing angle narrowing that would result from adding another optical layer.
Solution Approach 2:
The patent merges the protective function (scratch resistance) with the base film structure itself by dispersing heat-resistant particles within the polymer matrix. This combination approach integrates multiple functions (structural support, optical transmission, and scratch protection) into a single layer, avoiding the need for separate protection sheets and their associated complexity and viewing angle limitations.
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 effectively prevents deformation from heat and scratches, maintaining the prism sheet's functionality and enhancing brightness within the effective viewing angle of the LCD, with improved scratch resistance and restoration properties.
Implementation Method 1
a plurality of beads contained in the resin and scattering the incident light
Implementation Method 2
a plurality of prisms disposed on the base film, and refracting and condensing the light transmitted from the base film
Data Source
AI summary
The present invention relates to a prism sheet employed in a backlight unit. The prism sheet according to one embodiment of the present invention comprises a coating layer having a resin transmitting the incident light from the outside; and a plurality of beads contained in the resin and scattering the incident light; a base film disposed on the coating layer and transmitting the light; and a plurality of prisms disposed on the base film, and refracting and condensing the light transmitted from the base film. The prism sheet of the present invention may not be deformed even if the temperature of the backlight unit is increased.