Composite Optical Sheet for Newton's Ring Elimination
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Solution Overview
Problem
Existing optical sheets struggle to balance minimizing Newton's rings and maintaining brightness, as current manufacturing methods either fail to completely eliminate reflective Newton's rings or result in significant brightness loss when increasing haze to achieve this.
Innovation Solution
A composite optical sheet structure is formed using a mold with first and second concave shapes, where the second shapes are superimposed on the first to create a composite structure with a controlled haze ratio less than 2.8, optimizing the surface configuration to eliminate reflective Newton's rings while maintaining brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the haze of the surface is increased to eliminate Newton's ring, then Newton's ring is eliminated, but brightness drops significantly
Solution Approach 1:
The backside structure is divided into multiple convex lumps with different surface configurations. First convex lumps have smooth surfaces while second convex lumps have rough surfaces. This segmentation allows different regions to serve different functions: smooth regions maintain brightness while rough regions eliminate Newton's ring through increased local haze.
Solution Approach 2:
Different regions of the backside structure are given different surface qualities. The first convex lumps have smooth surfaces (lower haze) to preserve brightness in certain areas, while the second convex lumps have rough surfaces (higher haze) to eliminate Newton's ring in other areas. This local differentiation resolves the contradiction between overall brightness and Newton's ring elimination.
2Object-affected harmful factors
If the density of convex lumps is increased to eliminate Newton's ring, then Newton's ring elimination improves, but brightness loss increases
Solution Approach 1:
The convex lumps are segmented into two types with different densities and surface properties. First convex lumps have lower density and smooth surfaces, while second convex lumps have higher density and rough surfaces. This segmentation allows the system to achieve Newton's ring elimination through the combined effect of both types without requiring all lumps to be high-density rough-surfaced, thereby preserving brightness.
Solution Approach 2:
The backside structure uses a composite configuration of two types of convex lumps with different properties. This composite structure combines the advantages of both smooth and rough surfaces in a unified system, achieving both Newton's ring elimination and brightness preservation that cannot be obtained with a single type of convex lump.
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 composite structure effectively eliminates reflective Newton's rings with minimal brightness loss, achieving better anti-Newton's ring performance and brightness retention compared to single mold-cutting processes.
Implementation Method 1
Newton's ring results from light interference between two adjacent interfaces and often occurs between the bottom polarizing sheet and the top prism sheet or between the top prism sheet and the bottom prism sheet
Implementation Method 2
The surface configuration of the backside structure of the top prism sheet can be optimized to destroy the interference of the incident backlight and the incident environment light so as to eliminate Newton's ring
Data Source
AI summary
The present invention discloses a method of forming an optical sheet. The method comprises: providing a mold having a first surface; forming a plurality of first concave shapes on the first surface of the mold such that the first surface of the mold is changed to a second surface of the mold; forming a plurality of second shapes on the plurality of first concave shapes such that the second surface of the mold is changed to a third surface of the mold; and using the third surface of the mold to emboss a film on a substrate to form a composite structure corresponding to the combination of the plurality of first concave shapes and the plurality of second shapes.