Foamed Surface Light Guide for Uniform Emission
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing surface light source devices face challenges in achieving uniform light emission and wide viewing angles due to limitations in light diffuseness and directional control of light emission, particularly in the formation of fine concavo-convex structures on light guides, which often require complex molding processes and result in peaky light distribution and visibility issues.
Innovation Solution
A light guide with a foamed surface layer formed by laser etching, containing bubbles with a refractive index different from the light guide material, is used to enhance light diffuseness and directional control, allowing for a wide viewing angle and high emission quality without the need for a molding machine or complex molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a fine concavo-convex structure is formed on the light guide surface using conventional molding or laser processing, then light emission function is achieved, but the light distribution becomes peaky and viewing angle is narrowed
Solution Approach 1:
The patent applies porous materials by forming a foamed surface layer containing numerous bubbles on the light guide surface. The bubbles create a porous structure that scatters light in multiple directions, preventing peaky light distribution and widening the viewing angle while maintaining effective light emission function.
Solution Approach 2:
The patent changes the physical state of the light guide surface by creating a foamed layer with controlled bubble distribution. By adjusting parameters such as foam density, bubble size, and layer thickness, the patent optimizes both light emission intensity and viewing angle, resolving the contradiction between these two features.
2Illumination intensity
If a fine concavo-convex structure is formed by press molding with a molding member, then light emission mechanism is created, but production complexity increases and production efficiency decreases
Solution Approach 1:
The patent replaces the mechanical press molding system with a chemical foaming process. Instead of using a complex molding member with shape transfer surfaces, the patent uses a foaming agent that chemically transforms the light guide material into a foamed structure, significantly simplifying the manufacturing process and improving production efficiency.
Solution Approach 2:
The patent changes the manufacturing approach from mechanical forming to chemical transformation. By controlling parameters such as foaming agent concentration, heating temperature, and processing time, the patent achieves the desired light emission mechanism while maintaining high production efficiency.
3Illumination intensity
If blasting is applied to the molding member to create a fine concavo-convex structure, then light diffusion is improved, but the structure becomes complex and production time increases
Solution Approach 1:
The patent replaces the mechanical blasting process with a chemical foaming method. Instead of physically blasting the molding member to create surface structures, the patent uses chemical reactions to generate bubbles within the light guide material itself, eliminating the need for complex molding members and reducing production complexity.
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 foamed surface layer provides a broad luminance distribution and high emission quality, enabling light to be emitted uniformly and in a desired direction, improving the performance of surface light source devices by scattering light efficiently and reducing visibility of emission mechanisms.
Implementation Method 1
A light guide with a foamed surface layer formed by laser etching, containing bubbles with a refractive index different from the light guide material, is used to enhance light diffuseness and directional control
Implementation Method 2
containing bubbles with a refractive index different from the light guide material
Implementation Method 3
A light guide with a foamed surface layer formed by laser etching
Data Source
Figure 1~3
Figure 4~5
Figure 6~8b
AI summary
Disclosed is a plate-like light guide element (24) provided with a light incident surface, a light exit surface (242), and an underside surface (243) disposed on the opposite side of the light exit surface (242). A foamed surface layer (244) is formed on at least a part of at least either the light exit surface (242) or the underside surface (243). The foamed surface layer (244) contains air bubbles and has a recessed sectional surface including the normal direction of the light exit surface (242) or the underside surface (243). The light guide element (24) is produced by performing infrared laser etching for at least a part of at least one of the main surfaces of a plate-like light guide element material composed of an acryl resin plate produced by a continuous plate production method, to form the foamed surface layer (244).