Diffraction Light Guide Plate Molding for Uniformity and Low Haze
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Solution Overview
Problem
Existing diffraction light guide plates for virtual and augmented reality devices face issues with thickness uniformity, flatness, mechanical properties like pencil hardness and strength, and haze due to interfacial adhesion problems between plastic substrates and diffraction grating patterns, and the use of inorganic particles leads to optical losses.
Innovation Solution
A method for manufacturing a diffraction light guide plate with a diffraction grating pattern integrated on an optical layer without an interface, using a curable composition injected into a mold with a buffer spacer to ensure uniformity and mechanical strength, and a one-step process to form the pattern without additional resin layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If glass is used for high refractive index and light transmittance, then optical properties are improved, but weight increases and safety deteriorates
Solution Approach 1:
The patent changes the material parameter from glass to high-refractive plastic, achieving similar optical properties (refractive index 1.5-1.7) with significantly reduced weight and improved safety characteristics
Solution Approach 2:
The patent uses composite material structures including high-refractive plastic substrates with controlled internal structures to achieve glass-like optical performance while maintaining plastic advantages of light weight and safety
2Weight of moving object
If high-refractive plastic is used to replace glass, then weight is reduced and safety is improved, but surface flatness and thickness uniformity deteriorate
Solution Approach 1:
The patent applies preliminary surface treatment and precise mold design before the imprinting process to ensure that the high-refractive plastic substrate achieves the required surface flatness and thickness uniformity, preventing defects before they occur
Solution Approach 2:
The patent optimizes processing parameters including temperature, pressure, and curing conditions during manufacturing to achieve excellent surface flatness and thickness uniformity in high-refractive plastic materials
3Illumination intensity
If inorganic particles are added to realize high refraction, then refractive index is improved, but haze increases and interfacial adhesion deteriorates
Solution Approach 1:
The patent changes the approach from adding inorganic particles to using organic high-refractive plastic materials with inherently high refractive indices, eliminating particle-related haze and adhesion problems while achieving the desired optical performance
4Manufacturing precision
If a multi-step imprinting process is used to form diffraction grating, then diffraction pattern is improved, but manufacturing complexity increases and mechanical properties deteriorate
Solution Approach 1:
The patent combines the substrate formation and diffraction grating imprinting into a single integrated molding process, eliminating intermediate steps, reducing manufacturing complexity, and improving mechanical properties by avoiding repeated handling and interface creation
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 method achieves high refractive index, low haze, excellent thickness uniformity, and mechanical properties, enabling high-resolution and bright images in virtual reality devices by minimizing interfacial issues and optical losses.
Implementation Method 1
a curable composition which includes a monomer or a compound having an episulfide group and a thiol compound
Data Source
Figure 1~2
AI summary
The present disclosure relates to a diffraction light guide plate that has excellent thickness uniformity and flatness, and at the same time, has low haze, and excellent mechanical properties such as pencil hardness and strength, and a method for manufacturing the diffraction light guide plate.