Wide heart-shaped mini-LEDs without a second lens as a large area, ultra-high luminance, and flat light source

In recent years, the demand for outdoor advertising and industrial display applications has been steadily increasing. Outdoor environments require higher brightness levels, thus requiring a reduction in the thermal resistance of the light source package. However, using secondary optical lenses to decrease the number of light sources is not a suitable solution because it may lead to the issue of lens detachment. Therefore, this paper proposes a packaging structure for wide heart-shaped angular light distribution mini-light emitting diodes (WHS mini-LEDs) with a primary optical design to enhance the light-emitting angle. The chips are directly bonded to an aluminum substrate using the metal eutectic process to minimize thermal resistance in the packaging. The experimental results indicated that the WHS mini-LED package had a total thermal resistance of 6.7 K/W. In a 55-inch backlight module (BLM), only 448 WHS mini-LEDs coupled with a quantum dot (QD) film and a brightness enhancement film (BEF) were required. Each lamp board was operated at 20.5 V and 5.5 A. The average luminance of the liquid crystal module (LCM) can reach 2234.2 cd/m² with a uniformity of 90% and an NTSC value of 119.3%. This design offers a competitive advantage for outdoor advertising displays and industrial displays that require large areas, high brightness, and high color saturation.