Quantum Dot Lens with Resin Encapsulation for Backlight Uniformity
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Solution Overview
Problem
Existing quantum dot backlight modules suffer from poor light uniformity, blue light leakage, and high manufacturing costs due to the use of expensive quantum dot phosphors and inefficient 3D printing methods, which restrict mass production and result in low light extraction efficiency and undesirable light spot patterns.
Innovation Solution
A quantum dot lens design featuring a convex and concave lens structure with a quantum dot fluorescent resin layer between them, where the lenses are manufactured using high-temperature injection molding and laser etching, allowing for efficient encapsulation and photocuring of the resin, thereby enhancing light consistency and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If quantum dot phosphors are used in LED backlight modules, then color rendering is improved, but manufacturing cost increases and reliability decreases due to sensitivity to high temperature, water, and oxidation
Solution Approach 1:
The patent uses a resin layer as a protective shell encapsulating the quantum dot phosphors, replacing the traditional sandwich structure with barrier films. This resin layer provides protection against water and oxidation while maintaining the optical properties of quantum dots, thereby improving reliability without sacrificing color rendering performance
Solution Approach 2:
The patent creates a composite structure by mixing quantum dot phosphors with resin material to form a quantum dot lens. This composite approach integrates the quantum dots within a protective matrix that provides environmental stability, solving both the color rendering and reliability issues simultaneously
2Illumination intensity
If quantum dot phosphors are coated or attached to form quantum dot lenses, then color rendering is improved, but light uniformity deteriorates and blue light leakage occurs
Solution Approach 1:
The patent achieves homogeneous distribution of quantum dot phosphors by mixing them uniformly with resin material in a specific weight ratio (0.1-10 parts quantum dots per 100 parts resin). This homogeneous mixture ensures uniform light emission and prevents blue light leakage, improving manufacturing precision while maintaining color rendering
3Adaptability or versatility
If 3D printing method is used to manufacture quantum dot lenses, then manufacturing flexibility is improved, but productivity deteriorates due to low efficiency and difficulty in mass production
Solution Approach 1:
The patent replaces the 3D printing mechanical process with injection molding technology. The quantum dot lens is manufactured by injecting a resin containing quantum dot phosphors into a mold, allowing for high-speed mass production while maintaining design flexibility. This substitution dramatically improves productivity for mass production applications
4Productivity
If quantum dot phosphors are mixed with lens materials for injection molding, then manufacturing efficiency is improved, but manufacturing cost increases due to high material requirements
Solution Approach 1:
The patent optimizes the concentration parameter of quantum dot phosphors in the resin mixture, using only 0.1-10 parts by weight per 100 parts of resin. This parameter optimization maintains sufficient luminescence efficiency while dramatically reducing the quantity of expensive quantum dot materials required, lowering manufacturing cost while preserving manufacturing efficiency
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 ensures uniform and consistent light emission, prevents blue light leakage, and simplifies the manufacturing process, making it suitable for mass production while reducing the amount of quantum dot material needed, thus lowering costs and improving light extraction efficiency.
Implementation Method 1
quantum dot phosphors have received widespread attention in the LED backlight industry for a series of unique optical properties such as an adjustable spectrum with the size, a small full width at half maximum (FWHM), a small Stokes shift, a high excitation efficiency
Implementation Method 2
The lens is configured to diffuse a point source of LED light as isotropic scattering light as much as possible to increase the divergence angle of the LED light
Implementation Method 3
The lens is configured to diffuse a point source of LED light as isotropic scattering light as much as possible
Implementation Method 4
Since the quantum dot materials are not resistant to high temperatures and water and are easily oxidized, methods for how to better solve failures of quantum dots
Implementation Method 5
a manufacturing method of the quantum dot lens
Data Source
AI summary
A quantum dot lens, a backlight module, a display device and a manufacturing method of the quantum dot lens are provided. The quantum dot lens includes: a first lens, which is a convex lens and is provided with a first lens surface; a second lens, which is a concave lens and is provided with a second lens surface opposite to the first lens surface; and a quantum dot fluorescent resin layer, provided between the first lens surface and the second lens surface, and including more than one quantum dot fluorescent material. With the above structure, the quantum dot lens has a simple manufacturing process and ease of mass production, saves the quantum dot fluorescent material, and solves the problems of poor consistency and blue light leakage of existing quantum dot lenses.