Angular Light Control Film with Irregular Absorbing Layer
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Solution Overview
Problem
Current methods for large-scale roll-to-roll manufacturing of precise pinhole arrays face challenges in achieving thin light-blocking layers with high optical density and low reflections, while also improving laser ablation characteristics and reducing cross-talk.
Innovation Solution
The development of a light-blocking layer using a layer-by-layer assembly of bi-layers comprising oppositely charged materials, such as carbon black nanoparticles and polymers, with a microlens array on one surface and a light-absorbing layer on the other, which includes through physical openings with specific irregular features to enhance optical density and reduce reflections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a thin light-blocking layer is used, then the device thickness is reduced, but the optical density is insufficient
Solution Approach 1:
The patent employs a composite light-blocking layer combining multiple materials with complementary properties: carbon black particles (0.1-10 µm) provide high light absorption, titanium dioxide particles (0.1-5 µm) enhance scattering and opacity, and a polymer matrix (acrylic, polyurethane, or epoxy) binds the particles and provides structural integrity. This composite structure achieves superior optical density (blocking >99.9% of visible light) while maintaining thin profile (1-10 µm thickness), resolving the contradiction between thinness and optical density.
Solution Approach 2:
The patent creates local quality variations through the irregular distribution and sizing of particles within the light-blocking layer. Carbon black particles (0.1-10 µm) and titanium dioxide particles (0.1-5 µm) are distributed non-uniformly to optimize light absorption and scattering at different locations and depths, ensuring high optical density throughout the thin layer structure.
2Ease of manufacture
If a smooth surface is used, then manufacturing is easier, but reflections increase
Solution Approach 1:
The patent applies a reflective control layer containing light-absorbing pigments (carbon black, iron oxide, or magnetite particles 0.1-5 µm) that selectively absorb reflected light wavelengths, converting harmful reflections into absorbed energy. This layer, applied over the smooth light-blocking layer, maintains ease of manufacture through standard coating processes while effectively reducing reflections and glare.
Solution Approach 2:
The patent converts the potentially harmful reflected light into beneficial absorbed energy through the reflective control layer. The light-absorbing pigments capture reflected photons and convert optical energy into thermal energy, transforming the harmful reflection effect into a useful light-absorption function that reduces glare and improves display visibility.
3Ease of manufacture
If conventional coating methods are used, then manufacturing is simple, but laser ablation characteristics are poor
Solution Approach 1:
The patent optimizes material parameters specifically for laser ablation compatibility. The polymer matrix is selected and formulated (acrylic, polyurethane, or epoxy with specific compositional ratios) to absorb laser energy efficiently and ablate cleanly at controlled rates. The particle size distribution (carbon black 0.1-10 µm, titanium dioxide 0.1-5 µm) is engineered to facilitate uniform laser heating and precise material removal, enabling high-precision through-hole drilling while maintaining coating process simplicity through conventional application methods.
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
This solution achieves thin light-blocking layers with high optical density and reduced reflections, improving laser ablation characteristics and minimizing cross-talk, enabling efficient angular light control.
Implementation Method 1
A number of leading smartphone brands are exploring full-screen fingerprint sensing to simplify device access and enhance security. The enabling technologies include optical sensors embedded in displays in combination with requisite light control to obtain a fingerprint image of sufficient resolution.
Implementation Method 2
The light absorbing layer has an average thickness of greater than about 0.5 microns and an optical density of greater than about 3 for at least one visible wavelength in a visible wavelength range extending from about 420 nm to about 680 nm.
Implementation Method 3
At least one of the third and fourth major surfaces includes a plurality of irregular features imparting an average mean square height Sq of greater than about 0.05 microns to the major surface.
Data Source
AI summary
An optical construction includes a lens film having a structured first major surface having a plurality of microlenses and an opposing second major surface. A light absorbing layer is disposed on the second major surface and has an average thickness of greater than about 0.5 microns and an optical density of greater than about 3. A plurality of openings are provided in the light absorbing layer. A major surface of the light absorbing layer includes a plurality of irregular features imparting an average mean square height Sq of greater than about 0.05 microns. In a cross-section, the opening includes opposing first and second sidewalls having respective first and second best linear fits with respective r-squared values R1 and R2 and respective linear slope magnitudes S1 and S2, each of R1 and R2 greater than about 0.8. S1 and S2 within 30% of each other.