Light-Control Member with Support Section for Roll-to-Roll Stability
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Solution Overview
Problem
The manufacturing process of light-control members often results in deformation and separation issues due to concentrated load on step portions between substrate ends, particularly when using roll-to-roll processes, leading to defects and suboptimal optical performance.
Innovation Solution
A mother substrate design with light-shielding layers in specific areas and a light-diffusion section formed using a photosensitive resin layer, where the light-diffusion section has a larger area than the light-shielding layers, and a support section with a wider area to distribute load evenly, preventing deformation and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the light-diffusion section is formed with a narrower width than the substrate, then contamination of the rear side of the substrate or laminating device is prevented, but the light-diffusion section deforms due to concentrated load on step portions between substrate ends and the light-diffusion section
Solution Approach 1:
The patent applies a transparent negative resist not only in the light-diffusion section area but also in both end areas of the substrate before the light-diffusion section. This preliminary extension of the resist layer creates a broader support base that prevents load concentration on step portions during winding, thereby preventing deformation while the resist width is controlled to avoid contamination.
2Object-affected harmful factors
If the transparent negative resist layer is formed with a width narrower than the substrate, then contamination is avoided, but the area where the light-diffusion section and substrate are closely adhered is small, causing separation when peripheral portions are subjected to force
Solution Approach 1:
The transparent negative resist is preliminarily applied in extended areas at both ends of the substrate before the light-diffusion section. This creates additional adhesion zones where the resist closely adheres to the substrate, providing reliable bonding that prevents separation when peripheral portions are subjected to force during the winding process.
3Illumination intensity
If the light-diffusion section has a V-shaped cross section with light absorption layer, then light diffusion is achieved through total reflection on groove wall surfaces, but manufacturing defects occur due to load concentration and deformation in roll-to-roll processes
Solution Approach 1:
The transparent negative resist is applied in advance in both end areas of the substrate before the light-diffusion section area. This preliminary extension provides structural support during the winding process, preventing deformation of the V-shaped grooves and ensuring manufacturing precision is maintained while achieving the desired light diffusion 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
This configuration enhances optical performance by preventing defects in the manufacturing process, ensuring the light-control member maintains structural integrity and optical quality.
Implementation Method 1
light-shielding layers provided in a first area in the light-control member formation area
Implementation Method 2
a reflective surface which is in contact with the light emitting end surface and the light incident end surface and on which light incident from the light incident end surface is reflected
Implementation Method 3
a light-diffusion section provided in an area other than the light-shielding layers in the first area and formed of light transmitting material
Data Source
AI summary
A light-control member (13) includes a substrate (39); light-shielding layers (40) provided in a first area (A1) on one surface (39a) of the substrate (39); a light-diffusion section (41) provided in an area other than the light-shielding layers (40) in the first area (A1) and formed of light transmitting material; and a support section(45) provided in a second area (A2) positioned on an outer side of the first area (A1) on the one surface (39a), in which the light-diffusion section (41) has a light emitting end surface (41a) in contact with the one surface (39a) of the substrate (39), a light incident end surface (41b) opposing the light emitting end surface (41a) and having an area greater than an area of the light emitting end surface (41a), and a reflective surface (41c) which is in contact with the light emitting end surface (41a) and the light incident end surface (41b) and on which light incident from the light incident end surface (41b) is reflected, and a formation area of the support section (45) per unit area in the second area (A2) is greater than a formation area of the support section (45) per unit area in the first area (A1).