Curved Light Diffusion Member Edge Angle Design
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Solution Overview
Problem
A light diffusion member with micro-lenses on a curved surface in head-up display devices often experiences a large gradient at the edge, leading to potential mold interference and shape collapse during the molding process, which can deteriorate visibility.
Innovation Solution
A head-up display device with a light diffusion member featuring micro-lenses on a convex base surface where the edge angle is larger than the base surface angle change, preventing negative draft angles and mold interference, ensuring the shape is not easily broken and maintaining visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light diffusion member has a curved base surface with micro-lenses, then visibility is improved, but the edge gradient becomes large causing mold interference and shape collapse
Solution Approach 1:
The patent applies local quality by differentiating the edge angle requirements from the base surface angle change. The edge angle at the boundary between micro-lenses is designed to be larger than the base surface angle change amount, creating a local geometric property that prevents mold interference while maintaining the overall curved surface structure for visibility improvement.
Solution Approach 2:
The patent resolves the contradiction by introducing a new geometric dimension - the edge angle measured on a cross section orthogonal to the base surface. This additional angular dimension allows independent control of the edge geometry from the base surface curvature, enabling the edge angle to be optimized for mold release while the base surface angle change is optimized for visibility.
2Shape
If the base surface has a large angle change, then the curved surface effect is enhanced, but negative draft angles occur causing manufacturing difficulty
Solution Approach 1:
The patent applies local quality by making the edge angle at the micro-lens boundary locally larger than the base surface angle change amount. This local geometric enhancement at the edge region prevents negative draft angles during mold release while allowing the base surface to maintain its curved shape for optimal visual effect.
Solution Approach 2:
The patent applies preliminary action by designing the edge angle to be inherently larger than the base surface angle change before the molding process begins. This pre-designed geometric relationship ensures that negative draft angles are prevented from occurring in the first place, eliminating mold release issues before they can arise during manufacturing.
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 solution effectively prevents shape collapse and enhances visibility by ensuring the light diffusion member and mold do not interfere, maintaining the integrity of the micro-lens array and improving the display quality.
Implementation Method 1
a light diffusion member having a plurality of micro-lenses on a curved surface has been proposed as a means for improving visibility
Data Source
AI summary
A light diffusion member constituting a head-up display device includes multiple micro-lenses and has a curved base surface. The edge angle is larger than the base surface angle change amount. The edge angle is an angle formed by one of tangent lines of two micro-lenses and the other of the tangent lines passing through a boundary between two adjacent micro-lenses on a cross section orthogonal to the base surface. A reference line has a constant direction on the cross section, and a normal line passes at an arbitrary position on the base surface. The maximum value is θmax and the minimum value is θmin among angles between the normal line and the reference line. The base surface angle change amount is the absolute value of the difference between θmax and θmin.