Light Guide Device with Embedded Sources and Masking Structures
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Solution Overview
Problem
Existing light guiding devices for backlighting applications face challenges in mechanical durability and optical performance due to the complexity of integrating light sources at the edge of transparent plastic components, leading to potential mechanical damage and dark spots in the illumination pattern.
Innovation Solution
A light guide device comprising a base substrate with mounted light sources, encapsulated by guide layers with varying refractive indices and reflective scattering structures, which directs light internally and masks the light sources, enhancing mechanical protection and optical coupling while minimizing dark spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If light sources are distributed across the panel to minimize guiding length, then backlight thickness is reduced and efficiency is improved, but dark spots appear above the light sources
Solution Approach 1:
The light guide plate is segmented into multiple regions with different scattering structures. First scattering structures are positioned above light sources to mask them, while second scattering structures are positioned in dark spot regions to redirect light and eliminate不均匀ities. This segmentation allows targeted optical control in different zones of the light guide plate.
Solution Approach 2:
Different scattering structures are applied to different locations of the light guide plate. The first scattering structures (e.g., white ink dots or prisms) are located directly above light sources to mask their appearance, while second scattering structures are located in dark spot regions to redirect light. This local differentiation of scattering properties enables simultaneous achievement of source masking and dark spot elimination.
2Device complexity
If light sources are integrated by mechanical attachment at the edge of the transparent plastic component, then the device structure is simplified, but the production process complexity increases and mechanical damage susceptibility increases
Solution Approach 1:
The light source integration process is merged with the light guide plate manufacturing process. The light guide plate is injection molded with embedded light source cavities and integrated scattering structures (white ink dots, prisms, or micro-lenses) formed during the same molding cycle. This combining of operations eliminates separate assembly steps and reduces production complexity.
Solution Approach 2:
The scattering structures are preliminarily formed into the light guide plate during injection molding, before the light sources are installed. The cavities for light sources and the scattering structures are created in advance during the molding process, so that when light sources are later inserted, the optical control features are already in place. This preliminary formation of optical structures simplifies the overall manufacturing process.
3Illumination intensity
If scattering structures or films are located within or on the surface of the transparent guide to achieve perpendicular light emission, then backlighting performance is improved, but the device thickness increases
Solution Approach 1:
The scattering structures are implemented as thin surface features directly on the light guide plate rather than as separate thick components. White ink dots, surface prisms, or micro-lenses are formed as thin film or surface modifications during injection molding. These thin scattering structures achieve the required light redirection and masking functions while adding minimal thickness to the overall device.
Solution Approach 2:
The light guide plate performs multiple functions simultaneously: it guides light from edge-mounted sources, masks light sources through integrated scattering structures, eliminates dark spots through additional scattering structures, and provides structural support. By combining these functions into a single multi-functional component rather than separate elements, the overall device thickness is minimized while achieving all required optical performance.
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 solution provides a thin, efficient, and mechanically robust light guiding device with uniform light distribution, reduced power requirements, and a thinner structure, eliminating visible dark spots and simplifying the production process.
Implementation Method 1
light from the light source is guided through a transparent guide, typically made of plastic, by total internal reflection
Implementation Method 2
one or more scattering structures are located at the interface between the first and second guide layers and above the one or more sources of light
Data Source
Figure 1
AI summary
This invention relates to a light guide device and methods of manufacture. The light guide device is suitable for use in a range of applications, particularly in connection with the backlighting of displays, for example, liquid crystal displays. The light guide device comprises a combination of guide layers and one or more scattering structures in order to mask the appearance of one or more light sources.