LED Light Cover Sheet with Non-Random Surface Texture
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Solution Overview
Problem
Polymeric sheets for LED light cover applications face challenges in achieving balanced hiding power and light transmission, particularly in thin sheets where high diffuser loading is required, leading to economic difficulties and unsuitable performance for LED lighting applications.
Innovation Solution
A polymeric sheet with light diffusing particles and a non-random surface texture featuring specific unit structures such as hemispherical, ellipsoidal, and pyramidal shapes, which enhances hiding power and light transmission by providing a synergistic effect, allowing for lower diffuser loading while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diffuser loading is increased to improve hiding power, then hiding power is improved, but light transmission deteriorates
Solution Approach 1:
The patent segments the light diffusion function into two distinct components: (1) internal light diffusing particles dispersed in the polymeric material, and (2) external non-random surface texture with specific unit structures. This segmentation allows each component to contribute differently to hiding power while minimizing their individual impact on light transmission, thereby resolving the contradiction between hiding power and light transmission.
Solution Approach 2:
The patent creates a composite structure combining polymeric material with light diffusing particles and a non-random surface texture. This composite approach enables the sheet to achieve both good hiding power and light transmission by leveraging the complementary effects of the particles (providing base diffusion) and the surface texture (enhancing hiding power through geometric light scattering), without requiring excessive diffuser loading that would compromise light transmission.
2Productivity
If sheet thickness is decreased, then productivity is improved, but hiding power deteriorates
Solution Approach 1:
The patent changes the parameters of the surface structure by introducing a non-random surface texture with specific unit structures (such as hemispherical, pyramidal, or prismatic shapes) with controlled dimensions and spacing. This parameter change enables thin sheets to achieve sufficient hiding power through the geometric light scattering effects of the surface texture, compensating for the reduced thickness and eliminating the need to increase diffuser loading.
3Reliability
If diffuser loading is increased to achieve desired hiding power, then hiding power is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts part of the hiding power function from the bulk material (diffusing particles) and relocates it to the surface structure (non-random surface texture). This extraction reduces the amount of expensive diffusing particles required in the bulk material, thereby achieving the desired hiding power at lower manufacturing cost while maintaining optical performance.
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 sheet achieves improved hiding power and light transmission, with a Degree of Light Distribution (DLD) of at least 10° for down light applications and 30° for panel light applications, along with transmission rates of 85% or higher for down light applications, making it suitable for LED lighting systems.
Implementation Method 1
light diffusing particles (diffuser) in the sheet may improve the hiding power to some extent
Implementation Method 2
a non-random surface texture formed by unit structures on a surface of the sheet; wherein the surface texture comprises hemispherical structures, partial hemispherical structures, ellipsoidal structures, immersed spherical beads, ellipsoidal beads, 'bell-shape' bump, complex lens shape structures, pyramidal structures, reversed pyramidal structures
Implementation Method 3
a non-random surface texture formed by unit structures on a surface of the sheet
Data Source
AI summary
Disclosed herein is a sheet comprising a polymeric material; light diffusing particles disposed in the polymeric material; and a non-random surface texture on a surface of the sheet; wherein the surface texture comprises hemispherical structures, partial hemispherical structures, ellipsoidal structures, immersed spherical beads, ellipsoidal beads, “bell-shape” bump, complex lens shape structures, pyramidal structures, reversed pyramidal structures, or combinations comprising at least one of the foregoing. The sheet has excellent hiding power and transmission at the same time and is suitable for LED light cover applications. The unit structures have an aspect ratio of 0.15 to 0.5 and a pitch of greater than or equal to 100 μm.