Light Flux Controlling Member Gate Remnant Placement
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Solution Overview
Problem
Existing light flux controlling members formed by injection molding often suffer from light scattering due to gate remnants, which affect the desired light distribution characteristics, and reducing the gate thickness is not preferable due to moldability concerns.
Innovation Solution
A light flux controlling member is designed with a gate remnant formed on the back face, rather than the emission surface, to minimize the impact of gate remnants on light distribution, allowing for consistent light control and expansion while maintaining the gate thickness of the injection molding die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gate thickness of the injection molding die is reduced to minimize the impact of gate remnants on light distribution, then the light distribution characteristics are improved, but the moldability deteriorates
Solution Approach 1:
The patent inverts the conventional approach by positioning the gate remnant on the back face (opposite to the light emission surface) rather than on the emission surface itself. This inversion allows the gate to be located where it does not interfere with light distribution while maintaining standard gate thickness for good moldability. The light flux controlling member is designed with the light control emission surface facing away from the gate remnant, ensuring that the harmful gate remnant is positioned in a non-critical area for optical performance.
2Ease of manufacture
If the gate thickness is maintained for good moldability, then the ease of manufacture is improved, but light scattering occurs on the gate remnant affecting light distribution characteristics
Solution Approach 1:
The patent extracts the gate remnant from the light emission path by positioning it on the back face of the light flux controlling member. This separation removes the harmful element (gate remnant) from the critical optical zone, allowing the gate to maintain standard thickness for good moldability while preventing light scattering that would occur if the gate remnant were on the emission surface. The light flux controlling member structure is designed so that the gate remnant is spatially separated from the light control emission surface.
3Device complexity
If the gate remnant is positioned on the emission surface for structural simplicity, then the device complexity is reduced, but light scattering occurs affecting the desired light distribution
Solution Approach 1:
The patent resolves the contradiction by utilizing a different spatial dimension - moving the gate remnant from the light emission surface (front dimension) to the back face (rear dimension). This dimensional relocation maintains structural simplicity while eliminating light scattering issues. The light flux controlling member is designed with the gate positioned on the back face, effectively using the thickness dimension of the component to separate the gate remnant from the optical path without adding structural complexity.
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 design ensures superior light distribution characteristics and easy manufacturing, enabling uniform illumination even with reduced thickness of the surface light source apparatus and display apparatus.
Implementation Method 1
a light flux controlling member (140) that is formed by injection molding and controls a traveling direction of light emitted from a light emitting element (130)
Implementation Method 2
a light diffusion member (150) that transmits light from the light emitting apparatus (120) while diffusing the light
Data Source
AI summary
The present invention relates to light flux controlling member (140) formed by injection molding, light emitting apparatus (120) having light flux controlling member (140), surface light source apparatus (100) having light emitting apparatus (120), and a display apparatus having surface light source apparatus (100). Light flux controlling member (140) includes light control emission surface (141) configured to control light distribution of light emitted from light emitting element (130), and back face (142) opposite to light control emission surface (141). Light flux controlling member (140) is formed by injection molding by an overlap gate scheme, or by combination of the overlap gate scheme and a side gate scheme. Therefore, on back face (142) of light flux controlling member (140), there remains gate remnant (147) in such a manner to be in contact with an outer rim.