Light Guide Plate Luminance Uniformity via Iterative Dot Refinement
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Solution Overview
Problem
Conventional methods for manufacturing light guide plates often fail to achieve uniform luminance, requiring multiple mold remakes and increasing production costs due to inconsistencies in the resin injection molding process.
Innovation Solution
A method involving the iterative production of prototypes with primary and secondary light reflective dots, where secondary dots are added between primary dots to improve optical characteristics, allowing for refinement of the mold until satisfactory results are achieved, reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold with dot pattern determined by simulation is made and resin is injected to produce prototype, then the manufacturing process can be completed, but the luminance uniformity often fails to achieve target uniformity due to resin flow during injection molding
Solution Approach 1:
The patent applies preliminary action by pre-calculating resin flow effects during the simulation phase and compensating for them in the mold design. The dot distribution pattern is optimized in advance to account for expected resin flow variations, so that the final product achieves target luminance uniformity without requiring multiple mold remakes.
Solution Approach 2:
The patent implements feedback by using measured luminance uniformity data from prototypes to refine and optimize the dot distribution pattern. This feedback loop allows continuous improvement of the mold design based on actual performance, ensuring that subsequent production runs achieve the desired luminance uniformity.
2Manufacturing precision
If multiple mold remakes are performed to achieve target luminance uniformity, then the optical characteristics can be improved, but the production cost increases considerably
Solution Approach 1:
The patent performs preliminary optimization of the dot distribution pattern through simulation and calculation before actual mold production. By pre-determining the optimal pattern that compensates for resin flow effects, the need for expensive mold remakes is eliminated, thereby reducing production costs while maintaining high luminance uniformity.
Solution Approach 2:
The patent uses computer simulation to create a virtual model and optimize the dot distribution pattern before producing physical molds. This digital copying and testing approach allows multiple iterations of optimization without incurring the high costs of physical mold remakes, thereby reducing overall production costs.
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 approach ensures the production of light guide plates with improved optical characteristics at a lower cost by refining the mold through successive prototype testing and modification.
Implementation Method 1
the light reflecting surface has light diffusing reflective dots formed thereon in a desired distribution pattern to uniformly disperse light while the light is transmitted through the light guide plate
Data Source
AI summary
A method of producing an edge-light type light guide plate having a light exiting surface and a light reflecting surface having light reflective dots formed thereon in a scattered fashion. The method includes (a) producing a first prototype of the light guide plate having primary dots formed on the light reflecting surface, (b) examining optical characteristics of the first prototype relating to light exiting from the light exiting surface thereof, and (c) producing a second prototype of the lightguide plate when the examined first prototype exhibits unsatisfactory optical characteristics. The second prototype has primary dots that are the same as the primary dots of the first prototype in size and distribution, and secondary dots arranged between the primary dots in at least part of the light reflecting surface. The steps (b) and (c) are repeated until a prototype is produced which exhibits satisfactory optical characteristics.