Thin Film Lightguide with Reflective Release Liner
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Solution Overview
Problem
Conventional light emitting devices with edge-lit configurations using rigid lightguides are limited in thickness reduction, leading to large volumes and inflexible design, with challenges in achieving uniform light output due to artifacts from coupling lightguides and varying form factors.
Innovation Solution
A front illumination lightguide with a core layer thickness of less than 0.5 millimeters, featuring a pressure sensitive adhesive layer and a diffusely reflective release liner, which enhances light extraction and uniformity by redirecting light through a combination of light extraction features and diffusive reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If rigid lightguides with thickness of 2mm and larger are used, then light coupling is sufficient, but device thickness and volume cannot be reduced
Solution Approach 1:
The patent replaces rigid lightguides with thin film-based lightguides having thickness less than 0.5mm. The film structure enables flexible form factors and reduced device volume while maintaining light guiding functionality through optimized optical interfaces and coupling mechanisms.
Solution Approach 2:
The patent changes the thickness parameter of the lightguide from conventional 2mm+ to less than 0.5mm, and adjusts the refractive index of the adhesive layer to optimize light coupling efficiency in the thin film configuration, resolving the contradiction between thinness and coupling efficiency.
2Length of moving object
If thin lightguides with thickness less than 0.5mm are used, then device flexibility and thinness are improved, but uniform light output is difficult to achieve
Solution Approach 1:
The patent introduces an adhesive layer with specific refractive index (1.3-1.6) as an intermediary between the core layer and release liner. This intermediary layer optimizes optical coupling and light extraction, enabling uniform light output from the thin lightguide structure.
Solution Approach 2:
The patent creates a composite structure with core layer, adhesive layer, and release liner, where each layer has optimized optical properties. The composite design enables the thin lightguide to achieve uniform light output by combining materials with complementary refractive indices and optical characteristics.
3Strength
If conventional rigid frames are used, then structural support is adequate, but design flexibility and adaptability are limited
Solution Approach 1:
The patent replaces rigid frames with flexible film-based lightguides that can be conformally mounted to various surfaces and display configurations. The film structure provides sufficient structural support for optical functionality while enabling diverse design configurations and adaptability.
4Illumination intensity
If thick lightguides are used, then light mixing region is sufficient, but device thickness increases
Solution Approach 1:
The patent optimizes the thickness parameter to less than 0.5mm and adjusts the refractive index contrast between layers to enhance light extraction efficiency. This enables sufficient light mixing and extraction in a thin profile by optimizing optical parameters rather than relying on increased thickness.
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 enables thinner, more flexible light emitting devices with improved spatial luminance uniformity and reduced optical defects, allowing for more design configurations and efficient production methods.
Implementation Method 1
a pressure sensitive adhesive layer with a second refractive index less than the first refractive index... redirecting light through a combination of light extraction features and diffusive reflection
Implementation Method 2
a diffusely reflective release liner removably and optically coupled to the pressure sensitive adhesive layer... enhances light extraction and uniformity by redirecting light through a combination of light extraction features and diffusive reflection
Implementation Method 3
light is coupled into the core layer of the front illumination lightguide in a total internal reflection condition
Data Source
AI summary
A method of manufacturing a display includes coupling light from at least one light source into a front illumination film-based lightguide comprising a pressure sensitive adhesive layer between a core polymer film layer and a diffusely reflective release liner such that light from the at least one light source propagates by total internal reflection through the core polymer film layer, is extracted from the core polymer film layer, passes through the pressure sensitive adhesive layer, diffusely reflects from the diffusely reflective release liner and passes back through the pressure sensitive adhesive layer and core polymer film layer out of the front illumination film-based lightguide; analyzing the light exiting front illumination film-based lightguide from the at least one light source for defects; removing the diffusely reflective release liner from the front illumination film-based lightguide after analyzing; and laminating the front illumination film-based lightguide to a reflective spatial light modulator.