Extruded Light Guide Plate Scattering Pattern for Thin Backlight Units
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Solution Overview
Problem
There is a limitation in reducing the thickness of light guide plates manufactured using the injection method, which is a challenge in meeting the growing demand for smaller and thinner display apparatus.
Innovation Solution
The use of an extrusion method to manufacture light guide plates, incorporating a scattering pattern with specific protrusion and recess structures on the bottom surface, and a unique light exit surface design, along with an extrusion roller and roll stamper for forming the plates, allows for a thinner profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the injection method is used to manufacture light guide plates, then the manufacturing precision and quality are improved, but the thickness reduction is limited
Solution Approach 1:
The patent changes the manufacturing method from injection molding to extrusion molding, which fundamentally alters the process parameters and enables thinner light guide plate production. The extrusion method allows for continuous production with better thickness control and enables the use of scattering patterns that work effectively in thinner structures.
Solution Approach 2:
The patent introduces scattering patterns with specific local structures (protrusion portions and recess portions) on the bottom surface of the light guide plate. These localized scattering structures are strategically designed to maintain light guidance efficiency while enabling reduced thickness, as they create effective light scattering in the limited space available in thin plates.
2Length of moving object
If the thickness of light guide plate is reduced, then the thickness of backlight unit and display apparatus is reduced, but the light guidance efficiency deteriorates
Solution Approach 1:
The patent designs specific scattering patterns with protrusion portions and recess portions at localized positions on the bottom surface. These local scattering structures are positioned and sized to optimize light scattering efficiency in thin plates, ensuring that light is effectively redirected toward the viewing area despite the reduced thickness.
Solution Approach 2:
The scattering patterns include protrusion portions with curved or rounded surfaces rather than sharp edges. This curvature helps to diffuse light more effectively in multiple directions, maintaining light guidance efficiency in thinner plates where straight-line light paths are more limited by total internal reflection.
3Reliability
If scattering patterns with protrusion portions are formed on the bottom surface, then the light scattering efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent combines the formation of scattering patterns with the extrusion molding process itself. The extrusion die is designed to directly form the protrusion portions and recess portions as part of the light guide plate structure, eliminating the need for separate post-processing steps to create scattering patterns.
Solution Approach 2:
The extrusion molding process serves multiple functions simultaneously: it forms the basic light guide plate structure, creates the scattering patterns with protrusion portions, and establishes the required surface geometry. This multi-functionality reduces overall manufacturing complexity despite the added structural features.
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 results in a thinner light guide plate, which in turn reduces the thickness of the backlight unit and display apparatus, enhancing light guidance and reflection efficiency.
Implementation Method 1
a scattering pattern disposed on the bottom surface. The scattering pattern includes a first protrusion portion protruding from the bottom surface, a recess portion disposed along a circumference of the first protrusion portion and recessed from the bottom surface
Implementation Method 2
a bottom surface facing the light exit surface configured to reflect at least a portion of the incident light
Data Source
AI summary
A light guide plate includes a light incident surface to which a light is configured to be incident, a light exit surface from which the light incident through the light incident surface is configured to exit, a bottom surface facing the light exit surface configured to reflect at least a portion of the incident light, and a scattering pattern disposed on the bottom surface. The scattering pattern includes a first protrusion portion protruding from the bottom surface, a recess portion disposed along a circumference of the first protrusion portion and recessed from the bottom surface and a second protrusion portion spaced apart from the first protrusion portion and disposed along a portion of the recess portion.