Transparent Casting Compound Diffractive Surface Structure
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Solution Overview
Problem
The complexity and high manufacturing costs of existing lighting devices for displays, particularly those with tubular light sources, are exacerbated by the need for multiple foils and risk of malfunctions due to their intricate structure, which complicates production and increases costs.
Innovation Solution
A method for producing a self-luminous surface structure on a molded body using a solvent-free polymerized composition with a surface structure featuring diffractive elements, achieved by applying an impression composition containing partially fluorinated acrylates, non-fluorinated acrylates, and photoinitiators to a negative mold, which bonds to a transparent substrate, eliminating the need for additional films and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple foils are used in lighting devices, then light distribution and display illumination are achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines multiple functional foils into a single integrated shaped body with a complex internal structure. The shaped body integrates light guiding, scattering, and collimating functions that were previously performed by separate foils, thereby reducing device complexity while maintaining illumination performance
Solution Approach 2:
The shaped body serves multiple functions simultaneously: it acts as a light guide, contains scattering centers for light distribution, and has collimating surfaces for directing light. This multi-functionality eliminates the need for separate specialized foils, reducing both complexity and manufacturing costs
2Illumination intensity
If multiple foils are used in lighting devices, then light distribution is achieved, but manufacturing costs increase
Solution Approach 1:
The patent combines multiple functional foils into a single integrated shaped body with a complex internal structure. The shaped body integrates light guiding, scattering, and collimating functions that were previously performed by separate foils, thereby reducing device complexity and manufacturing costs
Solution Approach 2:
The patent uses injection molding with precise control of process parameters (temperature, pressure, material composition) to manufacture the complex shaped body in one step. This manufacturing approach reduces costs compared to assembling multiple separate foils, while maintaining the optical performance required for light distribution
3Illumination intensity
If conventional lighting device structure is used, then light illumination is achieved, but risk of malfunctions increases
Solution Approach 1:
The patent combines multiple functional foils into a single integrated shaped body with a complex internal structure. The shaped body integrates light guiding, scattering, and collimating functions that were previously performed by separate foils, thereby reducing device complexity and manufacturing costs
Solution Approach 2:
Instead of using multiple separate foils that require assembly and alignment, the patent inverts the approach by creating a single monolithic shaped body with integrated functions. This eliminates assembly errors, misalignment issues, and connection failures that plague multi-foil designs, thereby improving reliability
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 approach enables reliable and cost-effective production of self-luminous surface structures with precise replication of surface elements, reducing manufacturing costs and minimizing the risk of malfunctions by integrating luminescent pigments and optimizing the composition's viscosity and molar mass for improved optical quality and mechanical strength.
Implementation Method 1
a solvent-free polymerized composition a) 35 to 75% by weight of at least one partially fluorinated acrylate, b) 24.9 to 60% by weight of at least one non-fluorinated acrylate, and c) 0.1 to 5% by weight of at least one photoinitiator
Implementation Method 2
the layer on the surface facing away from the substrate has a surface structure with diffractive surface elements with a maximum structural size of defects in these surface elements of up to 100 nm
Implementation Method 3
The surface of the shaped body is structured in such a way that the light exits the light guide by refraction
Implementation Method 4
The object of the invention is to provide a method for producing a self-luminous surface structure of a molded body
Data Source
AI summary
Transparent molded part (I) comprises a sheet-like substrate and, provided on a major surface of the substrate, a layer having a layer thickness of 3-300 mu m and consisting of a solvent-free polymerized composition containing 35-75 wt.% of at least one partially fluorinated acrylate, 24.9-60 wt.% of at least one non-fluorinated acrylate, and 0.1-5 wt.% of at least one photoinitiator, where the layer has a surface structure with diffractive surface elements having a maximum structural size of defects of such surface elements of up to 100 nm on the surface facing away from the substrate. Transparent molded part (I) comprises a sheet-like substrate and, provided on a major surface of the substrate, a layer having a layer thickness of 3-300 mu m and consisting of a solvent-free polymerized composition containing 35-75 wt.% of at least one partially fluorinated acrylate, 24.9-60 wt.% of at least one non-fluorinated acrylate, and 0.1-5 wt.% of at least one photoinitiator, where the layer has a surface structure with diffractive surface elements having a maximum structural size of defects of such surface elements of up to 100 nm on the surface facing away from the substrate, and the composition contains luminescent pigments. Independent claims are included for: (1) pressureless process for the preparation of (I) comprising: providing a negative casting mold with shapings of surface elements; introducing the impression composition into the negative casting mold in an amount exceeding the shapings of the surface elements; applying a substrate to the exposed surface of the impression composition; polymerizing the impression composition to bond the layer of the impression composition with the substrate for preparing a molded part; and removing the finished molded part from the negative casting mold; and (2) impression composition comprising: 35-75 wt.% of least one partially fluorinated acrylate; 24.9-60 wt.% of at least one non-fluorinated acrylate; and 0.1-5 wt.% of at least one photoinitiator, where the composition contains luminescent pigments.