Irregular Prism Optical Substrates for Moire Reduction
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Solution Overview
Problem
Existing brightness enhancement films for flat panel displays often result in moire patterns due to interference between periodic patterns, and conventional methods to mitigate this issue are costly and inefficient, particularly when trying to produce a single substrate that enhances brightness while reducing moire effects.
Innovation Solution
A single optical substrate with a three-dimensionally varying, irregular prism structure on the light output surface and a smooth, planar light input surface, where the irregular prism structure comprises longitudinal irregular prism blocks with varying dimensions and orientations, reducing moire patterns and enhancing brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If two brightness enhancement films with periodic prismatic structures are used, then brightness enhancement is achieved, but moire patterns appear due to interference between the periodic patterns
Solution Approach 1:
The patent applies asymmetry by using an irregular prism structure where the pitch between adjacent peaks varies along the longitudinal direction. Specifically, the pitch changes from a first value to a second value, breaking the periodic symmetry that causes moire interference. This asymmetric pitch variation eliminates the regular interference patterns while maintaining the light redirecting function for brightness enhancement.
Solution Approach 2:
The patent implements local quality by having different pitch values in different regions of the prism structure. The pitch between adjacent peaks is not uniform but varies locally along the longitudinal direction, allowing each region to contribute to brightness enhancement while the overall variation prevents moire pattern formation across the entire surface.
2Object-affected harmful factors
If conventional manufacturing processes are used to rotate prismatic structures at an angle to reduce moire effect, then moire patterns are reduced, but production costs significantly increase due to required trimming
Solution Approach 1:
The patent eliminates the need for costly trimming and rotation operations by directly forming an asymmetric irregular prism structure during manufacturing. The varying pitch between adjacent peaks is built into the mold design, allowing the structure to reduce moire patterns without requiring post-manufacturing trimming or angular rotation, thus maintaining ease of manufacture while achieving moire reduction.
3Device complexity
If a single optical substrate integrates both brightness enhancement and moire reduction functions, then manufacturing complexity is reduced, but achieving both functions simultaneously is challenging
Solution Approach 1:
The patent merges both brightness enhancement and moire reduction functions into a single optical substrate by integrating the irregular prism structure directly into the substrate design. This combination eliminates the need for separate films or complex multi-layer structures, reducing manufacturing complexity while achieving both functions simultaneously through the varying pitch geometry.
Solution Approach 2:
The asymmetric irregular prism structure with varying pitch between adjacent peaks enables the single substrate to perform both functions: the prism geometry provides brightness enhancement through light redirection, while the pitch variation prevents moire pattern formation. This dual functionality is achieved through the geometric design rather than requiring separate components.
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 effectively reduces moire patterns and enhances brightness in flat panel displays, providing a cost-effective solution by integrating both functions into a single substrate, improving display quality without the need for complex manufacturing processes.
Implementation Method 1
brightness enhancement films use prismatic structures to direct light along the viewing axes
Implementation Method 2
prismatic structures to direct light along the viewing axes (i.e., normal to the display)
Data Source
AI summary
An optical substrate has a structured surface that enhances brightness and reduces moire effect. The optical substrate has a three-dimensionally varying, structured light output surface that comprises an irregular prismatic structure. The irregular prismatic structure may be viewed as comprising longitudinal prism blocks or rows thereof, arranged laterally defining peaks and valleys. Adjacent peaks, adjacent valleys, and/or adjacent peak and valley may be parallel or non-parallel, in an orderly, semi-orderly, random, or quasi-random manner. The lateral adjacent peaks, adjacent valleys, and/or adjacent peak and valley are not parallel. The adjacent irregular prism blocks may be irregular longitudinal sections having the same length, or random or quasi-random irregular sections having different lengths. The facets of each prism block may be flat, or curved (convexly and/or concavely).