Light Redirecting Film with Matte Layer for Display Brightness and Defect Masking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Display systems, such as LCDs, face challenges in enhancing brightness while masking physical and optical defects like scratches and moiré, with existing light redirecting films often compromising on optical clarity and haze to achieve this.
Innovation Solution
A light redirecting film with a structured surface featuring linear microstructures for redirecting light and a matte layer with controlled optical haze and clarity to enhance brightness and conceal defects, maintaining low optical haze and high optical clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a light redirecting film uses a matte layer with particles to mask defects, then defect masking capability is improved, but optical haze increases and optical clarity decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution (average size 0.5-2.0 microns with specific D10-D90 ranges), particle concentration (0.1-5.0 wt%), and layer thickness (3-10 microns) to achieve optimal defect masking while maintaining acceptable optical clarity. This quantitative optimization resolves the contradiction between defect masking and optical performance.
Solution Approach 2:
The patent uses composite materials by combining the matte layer with light redirecting microstructures (prisms or lenses) in a multi-layer configuration. The matte layer contains dispersed particles in a binder resin, creating a composite structure that provides both defect masking through scattering and light redirecting functionality, thereby maintaining optical clarity while masking defects.
2Illumination intensity
If a light redirecting film increases brightness through microstructures, then display brightness is improved, but optical defects like scratches become more visible
Solution Approach 1:
The patent merges two previously separate functions into a single integrated film: the light redirecting microstructures (prisms or lenses) are combined with the matte scattering layer containing particles. This unified structure simultaneously redirects light to enhance brightness and scatters light to mask scratches and other optical defects, resolving the contradiction between brightness enhancement and defect visibility.
Solution Approach 2:
The light redirecting film achieves multi-functionality by incorporating both light redirecting microstructures and a matte layer with particles. The film simultaneously performs brightness enhancement through light redirection and defect masking through scattering, eliminating the need for separate films and resolving the contradiction between improving brightness and hiding defects.
3Illumination intensity
If a light redirecting film uses a smooth surface, then optical clarity is maintained, but defect masking capability is reduced
Solution Approach 1:
The patent applies local quality by creating a matte layer with specific local optical properties (scattering capability) that is positioned only where needed to mask defects, while the rest of the film structure maintains smooth surfaces for optimal light redirection and clarity. The particle concentration and size are locally optimized in the matte layer to provide defect masking without significantly impacting overall optical clarity.
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 film effectively increases display brightness while masking defects like scratches and moiré, maintaining low optical haze and high optical clarity, thus improving display cosmetics without significant reduction in brightness.
Implementation Method 1
a first major surface that includes a plurality of first microstructures that extend along a first direction
Implementation Method 2
a matte layer that is disposed on the second major surface of the substrate layer and includes the second major surface of the light redirecting layer
Data Source
AI summary
Optical films, optical stacks including the optical films, and display systems including the optical films are described. The optical film includes a first major surface that may include a plurality of first microstructures that extend along a first direction. The optical film also includes a second major surface that is opposite to the first major surface and includes a plurality of second microstructures. The second major surface has an optical haze that is not greater than about 3% and an optical clarity that is not greater than about 85%.