Ultra Thin Display Module Using Embedded LED and Secondary Lens
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Solution Overview
Problem
Current liquid crystal display modules are not thin enough due to limitations in the thickness of components within the backlight module, which cannot be further reduced beyond a certain minimum thickness.
Innovation Solution
An ultra thin display module is designed comprising a LED substrate, LED lamp beads, and a secondary lens with fluorescence coatings, where the LED lamp beads are embedded in grooves or encapsulated within the secondary lens, eliminating the need for iron frames, reflective sheets, and optical films, resulting in a significantly thinner structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If traditional backlight module components (iron frames, reflective sheets, optical films) are used, then the structure provides sufficient lighting and support, but the thickness of the display module cannot be reduced below a minimum limit
Solution Approach 1:
The patent extracts and eliminates unnecessary components from the traditional backlight module structure. Specifically, it removes iron frames, reflective sheets, and multiple optical films, retaining only the essential elements (LED light source, secondary lens, and diffuse reflection layer) needed for lighting functionality. This extraction principle directly enables thickness reduction while maintaining sufficient lighting performance.
Solution Approach 2:
The patent merges multiple functions into fewer components. The secondary lens simultaneously performs light extraction, light redistribution, and protective functions. The diffuse reflection layer combines the roles of reflective sheet and light diffuser. This merging of functions reduces the number of separate components and overall module thickness.
2Length of stationary object
If the thickness of components in the backlight module is reduced, then the overall thickness decreases, but there is a minimum thickness limit that prevents further reduction
Solution Approach 1:
The patent employs thin film structures, particularly the diffuse reflection layer that can be applied as a thin coating on the secondary lens or LED substrate. This thin film approach replaces traditional thick components like reflective sheets and iron frames, enabling the module to achieve ultra-thin dimensions while maintaining structural integrity and lighting reliability.
Solution Approach 2:
The patent uses composite material structures where the secondary lens is made of transparent resin material that integrates multiple functional properties. The combination of the LED substrate, secondary lens, and diffuse reflection layer creates a composite structure that achieves both thinness and reliability, eliminating the need for separate thick support components.
3Length of stationary object
If a new ultra thin structure is adopted with LED substrate and secondary lens, then the thickness is greatly decreased, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-embedding the diffuse reflection layer onto the secondary lens before final assembly with the LED substrate. This pre-assembly step simplifies the overall manufacturing process by reducing the number of separate assembly operations needed, making the ultra-thin structure easier to manufacture despite its complex appearance.
Solution Approach 2:
The secondary lens structure is designed to self-align and self-support the LED lamp beads through its groove structure. The lens itself provides the mounting structure for the LEDs, eliminating the need for separate LED mounting frames or additional fastening components. This self-service design simplifies assembly while achieving ultra-thin dimensions.
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 new structure achieves a substantial reduction in the overall thickness of the display module, making it thinner than traditional designs while maintaining adequate backlight functionality.
Implementation Method 1
the outer surface of the top of the secondary lens is coated by fluorescence powders
Implementation Method 2
The plurality of LED lamp beads is disposed on the array of the LED substrate
Data Source
AI summary
The disclosure provides an ultra thin display module, comprising a LED substrate, a plurality of LED lamp beads, a secondary lens and a display panel. The plurality of LED lamp beads is disposed on the array of the LED substrate, the secondary lens is disposed on the LED substrate, the secondary lens is encapsuled inside the top surface of the LED lamp beads, and the display panel is disposed on the top surface of the secondary lens. The ultra thin display module and method for assembling the same of the disclosure use a brand new structure of ultra thin display module, such that the thickness of the module is greatly decreased as compared with the present techniques.