Light Distribution Structure with 3D Optical Cavities

Solution Overview

Problem

Conventional lightguide systems face challenges in controlling light distribution, particularly with multiple point light sources, leading to visible light streaks and wide angular extraction distributions, and are inefficient due to total internal reflection and the need for multiple layers, which increases costs and reduces optical performance.

Innovation Solution

A light distribution structure with a single optically functional layer featuring three-dimensional internal optical cavities that manage light propagation and extraction through total internal reflection, optimizing dimensions, periodicity, and orientation to control light distribution in both longitudinal and transverse directions without additional layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple separate optical films are used to control light distribution, then light distribution control capability is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvelight distribution control capabilityVSAvoidnumber of layers

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple optical functions (light extraction, angular distribution control, and brightness enhancement) into a single integrated optically functional layer with three-dimensional internal optical cavities, eliminating the need for multiple separate optical films while maintaining comprehensive light distribution control capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single optically functional layer performs multiple functions simultaneously: it extracts light from the lightguide medium, controls the angular distribution of extracted light, and enhances brightness, thereby serving as a universal component that replaces multiple specialized layers

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple separate optical films are used, then light distribution control is improved, but manufacturing cost increases

Engineering Contradiction:

Improvelight distribution control capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple optical functions (light extraction, angular distribution control, and brightness enhancement) into a single integrated optically functional layer with three-dimensional internal optical cavities, eliminating the need for multiple separate optical films while maintaining comprehensive light distribution control capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent transitions from two-dimensional surface patterns to three-dimensional internal optical cavities within a single layer, enabling complex optical functionality to be achieved in one component rather than requiring multiple stacked films

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Device complexity

If conventional lightguide solutions are used without brightness enhancement films, then device simplicity is maintained, but light distribution control capability deteriorates

Engineering Contradiction:

Improvenumber of layersVSAvoidlight distribution control capability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The single optically functional layer performs multiple functions simultaneously: it extracts light from the lightguide medium, controls the angular distribution of extracted light, and enhances brightness, thereby serving as a universal component that replaces multiple specialized layers

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Area of stationary object

If multiple point light sources are used, then illumination coverage is improved, but light streak formation occurs

Engineering Contradiction:

Improveillumination coverageVSAvoidlight streaks

Core Design Contradiction:

Area of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The patent employs three-dimensional internal optical cavities with specific geometric configurations that locally control light extraction and distribution, enabling uniform light mixing and redistribution from multiple point sources to eliminate visible light streaks while maintaining broad illumination coverage

Inventive Principle:

Principle #3Local quality

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 solution enables precise control over light extraction and distribution, reduces light leakage, and allows for cost-effective production of large surface area lightguides with enhanced optical performance, eliminating the need for multiple layers and improving illumination efficiency.

Implementation Method 1

by said essentially vertical surface the optical cavity is configured to extract light out of the structure in a predetermined direction essentially transverse to the longitudinal light propagation path

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

by said horizontal surface the optical cavity is configured to mediate light propagation in the light-transmitting carrier medium along an essentially longitudinal light propagation path

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS12153250B2Light distribution structure and element, related method and uses

Publication Date: 2024.11.26 NITTO DENKO CORP

AI summary

A method for manufacturing a light distribution structure in the form of an optically functional layer includes at least one three-dimensional feature pattern established in a light-transmitting carrier by a plurality of three-dimensional optical features. The method also includes manufacturing a patterned master tool for the at least one three-dimensional feature pattern by a piezoelectric cutting method selected from a fast tool servo method and a stylus engraving method, or by a laser engraving method, and transferring the at least one three-dimensional feature pattern onto the light-transmitting carrier.