IMSE Multilayer Structure Light Leakage Prevention
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Solution Overview
Problem
Existing multilayer structures in in-mould structural electronics (IMSE) face challenges such as light leakage and alignment difficulties, particularly when incorporating multiple optically functional components, which affect controllability, integration, weight, size, durability, and manufacturing complexity.
Innovation Solution
A method and structure involving a thermoplastic substrate film with optically functional elements and a light-blocking layer, where structural channels are formed to embed and isolate light-defining segments within an optically transmissive layer, reducing light leakage and improving alignment and integration by using a light-blocking layer to position and isolate optically functional elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple optically functional components are disposed in the same IMSE structure, then the functionality and integration level are improved, but light leakage and crosstalk phenomena occur
Solution Approach 1:
The patent divides the IMSE structure into multiple segments by introducing light-blocking walls that partition the structure into separate light-defining segments. Each optically functional component is contained within its own segment, preventing light from leaking between adjacent components. This segmentation maintains high integration level while eliminating light leakage and crosstalk.
Solution Approach 2:
The patent extracts the light-blocking function into a separate structural element (light-blocking walls made of opaque material) that is distinct from the optically functional components themselves. This allows the light-blocking function to be independently optimized and positioned to effectively prevent light leakage without interfering with the optical functionality of the components.
2Manufacturing precision
If alignment of substrate layer with subsequent layers is performed, then manufacturing precision is improved, but the manufacturing process becomes time-consuming and technically difficult
Solution Approach 1:
The patent incorporates alignment features (protrusions and recesses) directly into the mold structure during the molding process. These features automatically guide and align the substrate layer with subsequent layers as they are being formed, eliminating the need for separate alignment operations. This preliminary action ensures high alignment precision while keeping the manufacturing process simple and efficient.
Solution Approach 2:
The alignment features are designed to self-align the layers during the molding process itself. The protrusions on one layer automatically fit into recesses on the adjacent layer, creating automatic mechanical alignment without requiring external alignment equipment or complex positioning procedures. This self-service alignment reduces both time and technical complexity.
3Object-generated harmful factors
If light-blocking layer is introduced to isolate light-defining segments, then light leakage is prevented, but device complexity increases
Solution Approach 1:
The patent merges the light-blocking walls with the structural framework of the IMSE device. The same structural elements that provide mechanical support and define the geometry of the device also serve as light-blocking barriers. This combining of structural and optical functions prevents light leakage without adding separate complex light-blocking components, thereby maintaining relatively simple device structure.
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 enhances the alignment and integration of optically functional elements, reduces manufacturing complexity, and prevents light leakage, resulting in a more efficient and cost-effective production process for IMSE structures with improved durability and functionality.
Implementation Method 1
an optically substantially opaque light-blocking layer further disposed onto the first side of the substrate film, wherein the light blocking layer defines a (first) number of structural channels
Implementation Method 2
producing, preferably by moulding an optically transmissive layer upon the first side of the substrate film so that i) the light-defining segments including the number of optically functional elements are at least partially embedded in and optically coupled to the transmissive layer
Data Source
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AI summary
Described herein are embodiments of an optoelectronically functional multilayer structure. Also described herein are related methods of manufacturing an optoelectronically functional multilayer structure.