Light Guide Plate Grating Layout for Resin-Tolerant Image Quality
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Solution Overview
Problem
Existing nanoimprint methods struggle to precisely control the amount of resin material, leading to insufficient diffraction grating formation, which can cause wavefront disturbance, dispersion of diffraction efficiency, and deteriorated image quality in light guide plates used for extended reality applications.
Innovation Solution
A light guide plate design incorporating a diffraction grating with an adjacent layer thickness adjustment unit featuring an uneven region or blank region, where the pitch, height, and duty cycle of the uneven region change with distance from the diffraction grating, ensuring a thin and uniform residual layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a nanoimprint method is used to form a diffraction grating, then the diffraction grating can be formed with a resin material, but it is very difficult to strictly control the amount of the resin material
Solution Approach 1:
A release layer is formed on the mold surface before applying the resin material. This preliminary action creates a controlled interface that regulates resin material release, enabling precise control of the resin amount transferred to form the diffraction grating while maintaining ease of manufacture through the nanoimprint process
2Manufacturing precision
If the amount of resin material is inappropriate, then the formation of diffraction grating becomes insufficient, but strict control of resin material amount is very difficult
Solution Approach 1:
The release layer is prepared in advance on the mold, establishing a controlled mechanism that ensures appropriate resin material amount is transferred. This preliminary preparation guarantees sufficient diffraction grating formation while avoiding the difficulty of controlling resin amount during the actual molding process
Solution Approach 2:
The release layer acts as an intermediary between the mold and the resin material. It mediates the transfer of resin material, ensuring that the appropriate amount is transferred to form the diffraction grating without requiring direct precise control of the resin application process
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 suppresses image quality deterioration by maintaining diffraction efficiency and reducing modulation transfer function loss, even when precise resin material control is challenging.
Implementation Method 1
A diffraction grating that diffracts the image light is used in the light guide plate
Implementation Method 2
a substrate that totally internally reflects and guides light
Data Source
AI summary
There are provided a light guide plate, an image display device, and a method of manufacturing a light guide plate that suppress deterioration of the image quality even when the amount of a resin material cannot be strictly controlled. Provided is a light guide plate including: a diffraction grating that diffracts light; a layer thickness adjustment unit formed adjacent to the diffraction grating; and a substrate that totally internally reflects and guides light, in which the layer thickness adjustment unit includes an uneven region having a predetermined pitch or a blank region having a predetermined layer thickness, or both of the uneven region and the blank region.