Laminate Refractive Index Matching for Seamless Panel Assembly
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Solution Overview
Problem
Existing technologies are limited in producing larger transparent panels with deposited layers due to the size constraints of deposition equipment, leading to visible seams when smaller panels are used to form larger laminates.
Innovation Solution
A laminate configuration using a larger panel with smaller panels coupled to it, where a fill material with a refractive index matching that of the panels is used to fill gaps between them, making the seams less visible by matching the refractive indices of the transparent substrates, allowing for larger panel sizes without size restrictions from deposition tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If smaller panels are used to form larger laminates, then the laminate can be manufactured with existing deposition equipment, but visible seams appear between panels reducing appearance quality
Solution Approach 1:
A fill material is introduced as an intermediary substance between adjacent panels to optically bridge the gap. The fill material has a refractive index matched to the panel substrates, making the transition between panels imperceptible and eliminating visible seams while allowing the laminate to maintain its large overall size
Solution Approach 2:
The refractive index of the fill material is specifically selected to match or bridge the refractive indices of the adjacent panel substrates. By changing this optical parameter, the optical contrast at panel boundaries is eliminated, making seams invisible and resolving the appearance quality issue
2Manufacturing precision
If larger panels are manufactured directly, then seam visibility is eliminated, but deposition equipment size constraints prevent production
Solution Approach 1:
The large laminate is segmented into multiple smaller panels that can be individually manufactured using existing deposition equipment with size constraints. These panels are then assembled into a larger laminate configuration, enabling production with current equipment while achieving the desired large overall size
Solution Approach 2:
The fill material serves as a mediator that optically connects adjacent panels, making the segmented construction imperceptible. This allows the system to benefit from segmented manufacturing (ease of manufacture) while achieving the appearance of a seamless large panel
3Stability of the object's composition
If panels are assembled with gaps between them, then thermal expansion and structural stress are accommodated, but seam visibility increases
Solution Approach 1:
The refractive index of the fill material is specifically matched to the panel substrates to eliminate optical contrast at panel boundaries. This parameter matching ensures that gaps between panels become optically invisible, maintaining appearance quality while allowing the gaps to serve their structural function
Solution Approach 2:
The fill material provides localized optical matching at panel boundaries while allowing the bulk panels to maintain their structural properties. The refractive index matching is applied specifically at the interface regions where panels meet, providing local optical correction without affecting the overall structural stability of the laminate
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 configuration enables the creation of larger, seamless laminates by minimizing the visibility of seams between smaller panels, enhancing the appearance and structural integrity of the laminate, particularly useful for applications where larger panel sizes are required.
Implementation Method 1
The fill materials has a refractive index that is the same as or between the refractive indices of transparent substrates of the smaller panels. The refractive indices can help make seams between the smaller panels more difficult for humans to see
Data Source
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AI summary
A laminate can include a first panel and including a first transparent substrate having a first refractive index. The laminate can further include a second panel and a third panel, each coupled to the first panel. The second panel includes a second transparent substrate having a second refractive index, and the third panel includes a third transparent substrate having a third refractive index. The laminate can further include a fill material disposed within a gap between the second and third panels and having a fill material refractive index. The fill material refractive index is within 0.09 of the second refractive index, the third refractive index, or a value between the second and third refractive indices. Coupling may be direct or may be achieved with an adhesive film. The fill material can help to reduce the likelihood of seeing seams between the second and third panels.