Quantum Dot Acrylic Lens for High-Color-Gamut Backlight Modules
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Solution Overview
Problem
Existing quantum dot technologies for LCD backlight modules are costly and have low light conversion efficiency, leading to high production costs and undesirable display effects, with the challenge of encapsulating sensitive quantum dots in a water-free and oxygen-free environment.
Innovation Solution
A high-color-gamut quantum dot lens made of transparent acrylic material with a quantum dot light conversion material, coated with a water and oxygen-resistant layer, is integrated into the backlight module, enhancing light conversion efficiency and luminous spectra without altering the production process flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If quantum dot film technology is used to improve color gamut, then color gamut performance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive quantum dot films with a cost-effective alternative: a transparent resin lens containing quantum dot particles dispersed within the matrix. This approach uses cheaper materials and simplifies the structure while achieving comparable color gamut performance (DCI-P3 coverage), thereby significantly reducing manufacturing costs.
Solution Approach 2:
The patent creates a composite material by dispersing quantum dot particles within a transparent resin matrix to form an integrated lens structure. This composite approach combines the optical clarity of resin with the color conversion properties of quantum dots, achieving high color gamut performance without requiring separate quantum dot film layers, thus reducing manufacturing complexity and cost.
2Illumination intensity
If quantum dot materials are used to enhance color display, then color saturation is improved, but light conversion efficiency decreases
Solution Approach 1:
The patent applies quantum dot particles selectively within specific regions of the lens where color conversion is needed, rather than using uniform quantum dot films across the entire display. The transparent resin matrix allows light to pass through efficiently while quantum dots are concentrated in areas where they can effectively convert blue LED light to red and green wavelengths, optimizing both color saturation and light conversion efficiency.
Solution Approach 2:
The patent optimizes the size, concentration, and distribution parameters of quantum dot particles within the resin matrix to maximize light conversion efficiency. By controlling these parameters, the system achieves high color saturation while minimizing energy loss, as the quantum dots are positioned and sized to efficiently absorb blue light and emit red/green light with minimal non-radiative recombination.
3Ease of manufacture
If quantum dot reflective lens is used to reduce cost, then manufacturing cost is reduced, but light extraction efficiency decreases
Solution Approach 1:
The patent employs a lens structure with curved surfaces instead of flat reflective surfaces. The spherical or aspherical geometry of the lens enables efficient light refraction and focusing, improving light extraction efficiency compared to flat reflective designs. The curved interface between the resin lens and surrounding media optimizes light path control, ensuring high light extraction while maintaining cost-effectiveness.
Solution Approach 2:
The patent replaces reflective optical mechanisms with refractive mechanisms by using a transparent resin lens. Instead of relying on reflective surfaces to redirect light, the lens uses refraction at its curved interfaces to control light paths, improving light extraction efficiency. This substitution of optical mechanism maintains manufacturing simplicity while enhancing optical performance.
4Illumination intensity
If quantum dot film is used to achieve high color gamut, then color performance is improved, but production process complexity increases
Solution Approach 1:
The patent merges the quantum dot color conversion function with the lens structure by embedding quantum dot particles directly within the transparent resin matrix during lens fabrication. This integration eliminates the need for separate quantum dot film layers and their associated alignment and assembly processes, significantly simplifying production while maintaining high color performance.
Solution Approach 2:
The transparent resin lens serves multiple functions simultaneously: it acts as both the optical lens for light focusing and the quantum dot carrier for color conversion. This multi-functionality eliminates the need for separate components (lens + quantum dot film), reducing production process complexity while achieving high color gamut performance.
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 improves color gamut performance and brightness of LCD screens while reducing manufacturing costs by using a quantum dot lens that maintains uniform illumination and high color saturation, overcoming the limitations of previous quantum dot film technologies.
Implementation Method 1
The blue LED chip excites a photoluminescent material in the quantum dot film to obtain a white light source of an RGB three-color discontinuous spectrum
Implementation Method 2
an outer surface of the quantum dot lens body is sprayed with a water and oxygen resistant transparent coating
Implementation Method 3
a light source consists of a blue LED, a fluorescent powder, and a common transparent reflective (or refractive) type lens
Data Source
AI summary
A high-color-gamut quantum dot lens and a method for manufacturing a backlight module are provided. The method includes: mixing quantum dots with an acrylic resin, carrying out mixing granulation on the quantum dots and the acrylic resin by using an internal mixer to obtain quantum dot acrylic particles, carrying out injection molding on an acrylic material containing quantum dots to obtain a quantum dot lens, and then spraying a water and oxygen resistant transparent material on the surface of the injection-molded quantum dot lens for encapsulation. Light emitted from a white LED chip irradiates onto the quantum dot lens, and an RGB independent spectrum is superposed on a common fluorescent powder spectrum by means of a quantum dot light conversion material; and the superposed spectrum obtained thereby passes through an LCD screen, and a color display screen with a high color saturation and a wide color gamut will be obtained.